Polyethylene compositions, method of producing the same, fibers made therefrom, and method of making the same

ABSTRACT

The instant invention is a polyethylene composition, method of producing the same, fibers made therefrom, and method of making the same. The polyethylene composition according to instant invention comprises: (a) less than or equal to 100 percent by weight of the units derived from ethylene; and (b) less than 20 percent by weight of units derived from one or more α-olefin comonomers. The polyethylene composition according to instant invention has a density in the range of 0.920 to 0.970 g/cm 3 , a molecular weight distribution (M w /M n ) in the range of 1.70 to 3.5, a melt index (I 2 ) in the range of 0.2 to 1000 g/10 minutes, a molecular weight distribution (M z /M w ) in the range of less than 2.5, vinyl unsaturation of less than 0.1 vinyls per one thousand carbon atoms present in the backbone of the composition. The process for producing the inventive polyethylene composition comprises the steps of: (1) (co)polymerizing ethylene and optionally one or more α-olefin comonomers in the presence of a hafnium based metallocene catalyst via a gas phase (co)polymerization process in a single stage reactor; and (2) thereby producing the polyethylene composition having a density in the range of 0.920 to 0.970 g/cm3, a molecular weight distribution (M w /M n ) in the range of 1.70 to 3.5, a melt index (I 2 ) in the range of 0.2 to 1000 g/10 minutes, a molecular weight distribution (M z /M w ) in the range of less than 2.5, vinyl unsaturation of less than 0.1 vinyls per one thousand carbon atoms present in the backbone of the composition. The fibers according to the instant invention comprise a polyethylene composition comprising: (a) less than or equal to 100 percent by weight of the units derived from ethylene; and (b) less than 20 percent by weight of units derived from one or more α-olefin comonomers; wherein the polyethylene composition has a density in the range of 0.920 to 0.970 g/cm 3 , a molecular weight distribution (M w /M n ) in the range of 1.70 to 3.5, a melt index (I 2 ) in the range of 0.2 to 1000 g/10 minutes, a molecular weight distribution (M z /M w ) in the range of less than 2.5, vinyl unsaturation of less than 0.1 vinyls per one thousand carbon atoms present in the backbone of the composition. The process for making a fiber according to instant invention comprises the steps of: (1) selecting a polyethylene composition comprising: (a) less than or equal to 100 percent by weight of the units derived from ethylene; and (b) less than 20 percent by weight of units derived from one or more α-olefin comonomers; wherein the polyethylene composition has a density in the range of 0.920 to 0.970 g/cm 3,  a molecular weight distribution (M w /M n ) in the range of 1.70 to 3.5, a melt index (I 2 ) in the range of 0.2 to 1000 g/10 minutes, a molecular weight distribution (M z /M w ) in the range of less than 2.5, vinyl unsaturation of less than 0.1 vinyls per one thousand carbon atoms present in the backbone of the composition; (2) spinning the polyethylene composition into a fiber; and (3) thereby forming the fiber.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a non-provisional application claiming priority fromthe U.S. Provisional Patent Application No. 61/079,453, filed on Jul.10, 2008, entitled “TEXTILE FIBER FROM HDPE FOR SOFT WOVEN FABRICS,” theteachings of which are incorporated by reference herein, as ifreproduced in full hereinbelow.

FIELD OF INVENTION

The instant invention relates to polyethylene compositions, method ofproducing the same, fibers made therefrom, method of making the same,fabrics made from such fibers, and method of making such fabrics.

BACKGROUND OF THE INVENTION

The use of polymeric compositions such as polyolefins in producingfibers is generally known. Exemplary polyolefins include, but are notlimited to, polypropylene compositions. Such fibers may be formed intofabrics, e.g. woven fabrics or non-woven fabrics. Different techniquesmay be employed to form such fabrics. Such techniques are generallyknown to persons of ordinary skill in the art.

Despite the research efforts in developing compositions suitable forfibers, there is still a need for a polyethylene composition that isspinnable into a low denier/filament yarn with improved tenacity andhaptics. Furthermore, there is still a need for a process for producinga polyethylene composition that is spinnable into a low denier/filamentyarn with improved tenacity and haptics. Additionally, there is still aneed for polyethylene fibers that facilitate the production of woven andnon-woven fabrics having improved properties such as improved softnessand drapeability.

SUMMARY OF THE INVENTION

The instant invention is a polyethylene composition, method of producingthe same, fibers made therefrom, and method of making the same. Thepolyethylene composition according to instant invention comprises: (a)less than or equal to 100 percent by weight of the units derived fromethylene; and (b) less than 20 percent by weight of units derived fromone or more α-olefin comonomers. The polyethylene composition accordingto instant invention has a density in the range of 0.920 to 0.970 g/cm³,a molecular weight distribution (M_(w)/M_(n)) in the range of 1.70 to3.5, a melt index (I₂) in the range of 0.2 to 1000 g/10 minutes, amolecular weight distribution (M_(z)/M_(w)) in the range of less than2.5, vinyl unsaturation of less than 0.1 vinyls per one thousand carbonatoms present in the backbone of the composition. The process forproducing the inventive polyethylene composition comprises the steps of:(1) (co)polymerizing ethylene and optionally one or more α-olefincomonomers in the presence of a hafnium based metallocene catalyst via agas phase (co)polymerization process in a single stage reactor; and (2)thereby producing the polyethylene composition having a density in therange of 0.920 to 0.970 g/cm³, a molecular weight distribution(M_(w)/M_(n)) in the range of 1.70 to 3.5, a melt index (I₂) in therange of 0.2 to 1000 g/10 minutes, a molecular weight distribution(M_(z)/M_(w)) in the range of less than 2.5, vinyl unsaturation of lessthan 0.1 vinyls per one thousand carbon atoms present in the backbone ofthe composition. The fibers according to the instant invention comprisea polyethylene composition comprising: (a) less than or equal to 100percent by weight of the units derived from ethylene; and (b) less than20 percent by weight of units derived from one or more α-olefincomonomers; wherein the polyethylene composition has a density in therange of 0.920 to 0.970 g/cm³, a molecular weight distribution(M_(w)/M_(n)) in the range of 1.70 to 3.5, a melt index (I₂) in therange of 0.2 to 1000 g/10 minutes, a molecular weight distribution(M_(z)/M_(w)) in the range of less than 2.5, vinyl unsaturation of lessthan 0.1 vinyls per one thousand carbon atoms present in the backbone ofthe composition. The process for making a fiber according to instantinvention comprises the steps of: (1) selecting a polyethylenecomposition comprising: (a) less than or equal to 100 percent by weightof the units derived from ethylene; and (b) less than 20 percent byweight of units derived from one or more α-olefin comonomers; whereinthe polyethylene composition has a density in the range of 0.920 to0.970 g/cm³, a molecular weight distribution (M_(w)/M_(n)) in the rangeof 1.70 to 3.5, a melt index (I₂) in the range of 0.2 to 1000 g/10minutes, a molecular weight distribution (M_(z)/M_(w)) in the range ofless than 2.5, vinyl unsaturation of less than 0.1 vinyls per onethousand carbon atoms present in the backbone of the composition; (2)spinning the polyethylene composition into a fiber; and (3) therebyforming the fiber.

In one embodiment, the instant invention provides a polyethylenecomposition comprising: (a) less than or equal to 100 percent by weightof the units derived from ethylene; and (b) less than 20 percent byweight of units derived from one or more α-olefin comonomers; whereinthe polyethylene composition has a density in the range of 0.920 to0.970 g/cm³, a molecular weight distribution (M_(w)/M_(n)) in the rangeof 1.70 to 3.5, a melt index (I₂) in the range of 0.2 to 1000 g/10minutes, a molecular weight distribution (M_(z)/M_(w)) in the range ofless than 2.5, vinyl unsaturation of less than 0.1 vinyls per onethousand carbon atoms present in the backbone of the composition.

In one embodiment, the instant invention provides a polyethylenecomposition comprising: (a) less than or equal to 100 percent by weightof the units derived from ethylene; and (b) less than 20 percent byweight of units derived from one or more α-olefin comonomers; whereinthe polyethylene composition has a density in the range of 0.920 to0.970 g/cm³, a molecular weight distribution (M_(w)/M_(n)) in the rangeof 1.70 to 3.5, a melt index (I₂) in the range of 0.2 to 1000 g/10minutes, a molecular weight distribution (M_(z)/M_(w)) in the range ofless than 2.5, vinyl unsaturation of less than 0.1 vinyls per onethousand carbon atoms present in the backbone of the composition.

In one embodiment, the instant invention provides a polyethylenecomposition comprising: (a) less than or equal to 100 percent by weightof the units derived from ethylene; and (b) less than 20 percent byweight of units derived from one or more α-olefin comonomers; whereinthe polyethylene composition has a density in the range of 0.930 to0.960 g/cm³, a molecular weight distribution (M_(w)/M_(n)) in the rangeof 1.70 to 3.5, a melt index (I₂) in the range of 1 to 50 g/10 minutes,a molecular weight distribution (M_(z)/M_(w)) in the range of less than2.5, vinyl unsaturation of less than 0.06 vinyls per one thousand carbonatoms present in the backbone of the composition.

In one embodiment, the instant invention provides a polyethylenecomposition comprising: (a) less than or equal to 100 percent by weightof the units derived from ethylene; and (b) less than 20 percent byweight of units derived from one or more α-olefin comonomers; whereinthe polyethylene composition has a density in the range of 0.940 to0.955 g/cm³, a molecular weight distribution (M_(w)/M_(n)) in the rangeof 1.70 to 3.5, a melt index (I₂) in the range of 3 to 10 g/10 minutes,a molecular weight distribution (M_(z)/M_(w)) in the range of less than2.5, vinyl unsaturation of less than 0.06 vinyls per one thousand carbonatoms present in the backbone of the composition.

In one embodiment, the instant invention provides a polyethylenecomposition comprising: (a) less than or equal to 100 percent by weightof the units derived from ethylene; and (b) less than 20 percent byweight of units derived from one or more α-olefin comonomers; whereinthe polyethylene composition has a density in the range of 0.930 to0.955 g/cm³, a molecular weight distribution (M_(w)/M_(n)) in the rangeof 1.70 to 3.5, a melt index (I₂) in the range of 3 to 10 g/10 minutes,a molecular weight distribution (M_(z)/M_(w)) in the range of less than2.5, vinyl unsaturation of less than 0.06 vinyls per one thousand carbonatoms present in the backbone of the composition.

In one embodiment, the instant invention provides a polyethylenecomposition comprising: (a) less than or equal to 100 percent by weightof the units derived from ethylene; and (b) less than 20 percent byweight of units derived from one or more α-olefin comonomers; whereinthe polyethylene composition has a density in the range of 0.930 to0.955 g/cm³, a molecular weight distribution (M_(w)/M_(n)) in the rangeof 1.70 to 3.5, a melt index (I₂) in the range of 5 to 10 g/10 minutes,a molecular weight distribution (M_(z)/M_(w)) in the range of less than2.5, vinyl unsaturation of less than 0.06 vinyls per one thousand carbonatoms present in the backbone of the composition.

In one embodiment, the instant invention provides a polyethylenecomposition comprising: (a) less than or equal to 100 percent by weightof the units derived from ethylene; and (b) less than 20 percent byweight of units derived from one or more α-olefin comonomers; whereinthe polyethylene composition has a density in the range of 0.920 to0.960 g/cm³, a molecular weight distribution (M_(w)/M_(n)) in the rangeof 1.70 to 3.5, a melt index (I₂) in the range of 1 to 50 g/10 minutes,a molecular weight distribution (M_(z)/M_(w)) in the range of less than2.5, vinyl unsaturation of less than 0.06 vinyls per one thousand carbonatoms present in the backbone of the composition.

In an alternative embodiment, the instant invention further provides amethod for producing a polyethylene composition comprising the steps of:(1) (co)polymerizing ethylene and optionally one or more α-olefincomonomers in the presence of a hafnium based metallocene catalyst via agas phase (co)polymerization process in a single stage reactor; and (2)thereby producing a polyethylene composition having a density in therange of 0.920 to 0.970 g/cm³, a molecular weight distribution(M_(w)/M_(n)) in the range of 1.70 to 3.5, a melt index (I₂) in therange of 0.2 to 1000 g/10 minutes, a molecular weight distribution(M_(z)/M_(w)) in the range of less than 2.5, vinyl unsaturation of lessthan 0.1 vinyls per one thousand carbon atoms present in the backbone ofthe composition.

In an alternative embodiment, the instant invention further provides amethod for producing a polyethylene composition comprising the steps of:(1) (co)polymerizing ethylene and optionally one or more α-olefincomonomer in the presence of a hafnium based metallocene catalyst via agas phase (co)polymerization process in a single stage reactor; and (2)thereby producing the inventive polyethylene composition, wherein thepolyethylene composition has a density in the range of 0.920 to 0.970g/cm³, a molecular weight distribution (M_(w)/M_(n)) in the range of1.70 to 3.5, a melt index (I₂) in the range of 0.2 to 1000 g/10 minutes,a molecular weight distribution (M_(z)/M_(w)) in the range of less than2.5, vinyl unsaturation of less than 0.06 vinyls per one thousand carbonatoms present in the backbone of the composition.

In an alternative embodiment, the instant invention further provides amethod for producing a polyethylene composition comprising the steps of:(1) (co)polymerizing ethylene and optionally one or more α-olefincomonomer in the presence of a hafnium based metallocene catalyst via agas phase (co)polymerization process in a single stage reactor; and (2)thereby producing the inventive polyethylene composition, wherein thepolyethylene composition has a density in the range of 0.930 to 0.960g/cm³, a molecular weight distribution (M_(w)/M_(n)) in the range of1.70 to 3.5, a melt index (I₂) in the range of 1 to 50 g/10 minutes, amolecular weight distribution (M_(z)/M_(w)) in the range of less than2.5, vinyl unsaturation of less than 0.06 vinyls per one thousand carbonatoms present in the backbone of the composition.

In an alternative embodiment, the instant invention further provides amethod for producing a polyethylene composition comprising the steps of:(1) (co)polymerizing ethylene and optionally one or more α-olefincomonomer in the presence of a hafnium based metallocene catalyst via agas phase (co)polymerization process in a single stage reactor; and (2)thereby producing the inventive polyethylene composition, wherein thepolyethylene composition has a density in the range of 0.940 to 0.955g/cm³, a molecular weight distribution (M_(w)/M_(n)) in the range of1.70 to 3.5, a melt index (I₂) in the range of 3 to 10 g/10 minutes, amolecular weight distribution (M_(z)/M_(w)) in the range of less than2.5, vinyl unsaturation of less than 0.06 vinyls per one thousand carbonatoms present in the backbone of the composition.

In an alternative embodiment, the instant invention further provides amethod for producing a polyethylene composition comprising the steps of:(1) (co)polymerizing ethylene and optionally one or more α-olefincomonomer in the presence of a hafnium based metallocene catalyst via agas phase (co)polymerization process in a single stage reactor; and (2)thereby producing the inventive polyethylene composition, wherein thepolyethylene composition has a density in the range of 0.930 to 0.955g/cm³, a molecular weight distribution (M_(w)/M_(n)) in the range of1.70 to 3.5, a melt index (I₂) in the range of 3 to 10 g/10 minutes, amolecular weight distribution (M_(z)/M_(w)) in the range of less than2.5, vinyl unsaturation of less than 0.06 vinyls per one thousand carbonatoms present in the backbone of the composition.

In an alternative embodiment, the instant invention further provides amethod for producing a polyethylene composition comprising the steps of:(1) (co)polymerizing ethylene and optionally one or more α-olefincomonomer in the presence of a hafnium based metallocene catalyst via agas phase (co)polymerization process in a single stage reactor; and (2)thereby producing the inventive polyethylene composition, wherein thepolyethylene composition has a density in the range of 0.930 to 0.955g/cm³, a molecular weight distribution (M_(w)/M_(n)) in the range of1.70 to 3.5, a melt index (I₂) in the range of 5 to 10 g/10 minutes, amolecular weight distribution (M_(z)/M_(w)) in the range of less than2.5, vinyl unsaturation of less than 0.06 vinyls per one thousand carbonatoms present in the backbone of the composition.

In an alternative embodiment, the instant invention further provides amethod for producing a polyethylene composition comprising the steps of:(1) (co)polymerizing ethylene and optionally one or more α-olefincomonomer in the presence of a hafnium based metallocene catalyst via agas phase (co)polymerization process in a single stage reactor; and (2)thereby producing the inventive polyethylene composition, wherein thepolyethylene composition has a density in the range of 0.920 to 0.960g/cm³, a molecular weight distribution (M_(w)/M_(n)) in the range of1.70 to 3.5, a melt index (I₂) in the range of 1 to 50 g/10 minutes, amolecular weight distribution (M_(z)/M_(w)) in the range of less than2.5, vinyl unsaturation of less than 0.06 vinyls per one thousand carbonatoms present in the backbone of the composition.

In another alternative embodiment, the instant invention furtherprovides fibers comprising a polyethylene composition comprising: (a)less than or equal to 100 percent by weight of the units derived fromethylene; and (b) less than 20 percent by weight of units derived fromone or more α-olefin comonomers; wherein the polyethylene compositionhas a density in the range of 0.920 to 0.970 g/cm³, a molecular weightdistribution (M_(w)/M_(n)) in the range of 1.70 to 3.5, a melt index(I₂) the range of 0.2 to 1000 g/10 minutes, a molecular weightdistribution (M_(z)/M_(w)) in the range of less than 2.5, vinylunsaturation of less than 0.1 vinyls per one thousand carbon atomspresent in the backbone of the composition.

In another alternative embodiment, the instant invention furtherprovides a method for making fibers comprising the steps of: (1)selecting a polyethylene composition comprising: (a) less than or equalto 100 percent by weight of the units derived from ethylene; and (b)less than 20 percent by weight of units derived from one or moreα-olefin comonomers; wherein the polyethylene composition has a densityin the range of 0.920 to 0.970 g/cm³, a molecular weight distribution(M_(w)/M_(n)) in the range of 1.70 to 3.5, a melt index (I₂) in therange of 0.2 to 1000 g/10 minutes, a molecular weight distribution(M_(z)/M_(w)) in the range of less than 2.5, vinyl unsaturation of lessthan 0.1 vinyls per one thousand carbon atoms present in the backbone ofthe composition; (2) spinning the polyethylene composition into a fiber;and (3) thereby forming the fiber.

In another alternative embodiment, the instant invention furtherprovides a fabric comprising a fiber comprising a polyethylenecomposition comprising: (a) less than or equal to 100 percent by weightof the units derived from ethylene; and (b) less than 20 percent byweight of units derived from one or more α-olefin comonomers; whereinthe polyethylene composition has a density in the range of 0.920 to0.970 g/cm³, a molecular weight distribution (M_(w)/M_(n)) in the rangeof 1.70 to 3.5, a melt index (I₂) in the range of 0.2 to 1000 g/10minutes, a molecular weight distribution (M_(z)/M_(w)) in the range ofless than 2.5, vinyl unsaturation of less than 0.1 vinyls per onethousand carbon atoms present in the backbone of the composition.

In another alternative embodiment, the instant invention furtherprovides a method for fabricating a fabric comprising the steps of: (1)providing a fiber comprising a polyethylene composition comprising (a)less than or equal to 100 percent by weight of the units derived fromethylene; and (b) less than 20 percent by weight of units derived fromone or more α-olefin comonomers; wherein the polyethylene compositionhas a density in the range of 0.920 to 0.970 g/cm³, a molecular weightdistribution (M_(w)/M_(n)) in the range of 1.70 to 3.5, a melt index(I₂) in the range of 0.2 to 1000 g/10 minutes, a molecular weightdistribution (M_(z)/M_(w)) in the range of less than 2.5, vinylunsaturation of less than 0.1 vinyls per one thousand carbon atomspresent in the backbone of the composition; (2) fabricating the fiberinto a fabric via a process selected from the group consisting ofweaving process, knitting process, melt blown process, spunbond process,air laid process, needle punch process, hydroentangling process, electrospinning process, and combinations thereof.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the hafnium based catalyst is ahafnium based bis Cp metallocene catalyst.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the hafnium based catalyst is adimethyl hafnium based bis Cp metallocene catalyst.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the polyethylene composition has adensity in the range of 0.930 to 0.960 g/cm³, and a melt index (I₂) inthe range of 1 to 50 g/10 minutes.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the polyethylene composition has adensity in the range of 0.940 to 0.955 g/cm³, and a melt index I₂ in therange of 3 to 10 g/10 minutes.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the polyethylene composition has amolecular weight distribution (M_(w)/M_(n)) in the range of 1.70 to3.25.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the polyethylene composition has avinyl unsaturation of less than 0.05 vinyls per one thousand carbonatoms present in the backbone of the composition.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the polyethylene composition has lessthan 2 peaks on an elution temperature-eluted amount curve determined bycontinuous temperature rising elution fraction method at equal or above30° C., wherein the purge peak which is below 30° C. is excluded.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the polyethylene composition has 1peak or less on an elution temperature-eluted amount curve determined bycontinuous temperature rising elution fraction method at equal or above30° C., wherein the purge peak which is below 30° C. is excluded.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the polyethylene composition has only1 peak on an elution temperature-eluted amount curve determined bycontinuous temperature rising elution fraction method at equal or above30° C., wherein the purge peak which is below 30° C. is excluded.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the polyethylene composition has amolecular weight distribution (M_(z)/M_(w)) in the range of less than2.3.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the polyethylene compositioncomprises less than 15 percent by weight of the units derived from oneor more α-olefin comonomers.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the polyethylene compositioncomprises less than 11 percent by weight of the units derived from oneor more α-olefin comonomers.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the polyethylene compositioncomprises less than 7 percent by weight of the units derived from one ormore α-olefin comonomers.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the polyethylene compositioncomprises less than 5 percent by weight of the units derived from one ormore α-olefin comonomers.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the polyethylene compositioncomprises less than 3 percent by weight of the units derived from one ormore α-olefin comonomers.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the polyethylene composition issubstantially free of long chain branching.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the polyethylene composition is freeof long chain branching.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the polyethylene compositioncomprises less than 100 parts by weight of hafnium residues remainingfrom the hafnium based metallocene catalyst per one million parts ofpolyethylene composition.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fiber has a denier per filamentin the range of less than 50 g/9000 m.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fiber has a denier per filamentin the range of less than 40 g/9000 m.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fiber has a denier per filamentin the range of less than 30 g/9000 m.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fiber has a denier per filamentin the range of less than 20 g/9000 m.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fiber has a denier per filamentin the range of less than 10 g/9000 m.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fiber has a denier per filamentin the range of less than 5 g/9000 m.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fiber has a denier per filamentin the range of less than 3 g/9000 m.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fiber has a tenacity in the rangeof 0.1 to 5 g/denier.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fiber has a tenacity in the rangeof 1.5 to 5 g/denier.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fiber has a tenacity in the rangeof 2 to 5 g/denier.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fiber has a tenacity in the rangeof 2.0 to 4.5 g/denier.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fiber has a tenacity in the rangeof 2.5 to 4 g/denier.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fiber has a tenacity in the rangeof 2.5 to 3.5 g/denier.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fiber has an elongation measuredin percent of less than 1000.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fiber has an elongation measuredin percent of less than 300.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fiber has an elongation measuredin percent of less than 150.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fiber has an elongation measuredin percent of less than 100.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fiber has a boiling water shrinkmeasured in percent after being annealed at 120° C. in the range of lessthan 30.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fiber has a boiling water shrinkmeasured in percent after being annealed at 120° C. in the range of lessthan 20.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fiber has a boiling water shrinkmeasured in percent after being annealed at 120° C. in the range of lessthan 10.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fiber has a boiling water shrinkmeasured in percent after being annealed at 120° C. in the range of lessthan 2.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fiber is a staple fiber or acontinuous fiber.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fabric is selected from the groupconsisting of woven fabric, non-woven fabric, and combinations thereof.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the woven fabric has an abrasionresistance in the range of less 5 percent by weight of abraded fiber perweight of the fabric prior to abrasion testing.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the woven fabric has an abrasionresistance in the range of less 2 percent by weight of abraded fiber perweight of the fabric prior to abrasion testing.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the woven fabric has an abrasionresistance in the range of less 1 percent by weight of abraded fiber perweight of the fabric prior to abrasion testing.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the woven fabric has an abrasionresistance in the range of less 0.8 percent by weight of abraded fiberper weight of the fabric prior to abrasion testing.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fabric comprises one or morefibers having a denier per filament in the range of less than 5 g/9000m, e.g. 2 g/9000 m, and the fabric has a smoothness value in the rangeof less than 2.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fabric comprises one or morefibers having a denier per filament in the range of less than 5 g/9000m, e.g. 2 g/9000 m, and the fabric has a smoothness value in the rangeof less than 1.5, e.g. 1.3.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fabric comprises one or morefibers having a denier per filament in the range of less than 5 g/9000m, e.g. 2 g/9000 m, and the fabric has a wax value in the range ofgreater than 7, e.g. 7.5.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fabric comprises one or morefibers having a denier per filament in the range of less than 5 g/9000m, e.g. 2 g/9000 m, and the fabric has a hand friction value in therange of less than 3.5.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fabric comprises one or morefibers having a denier per filament in the range of less than 5 g/9000m, e.g. 2 g/9000 m, and the fabric has a hand friction value in therange of less than 3.0.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fabric comprises one or morefibers having a denier per filament in the range of less than 5 g/9000m, e.g. 2 g/9000 m, and the fabric has a hand friction value in therange of less than 2.5.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fabric comprises one or morefibers having a denier per filament in the range of less than 5 g/9000m, e.g. 2 g/9000 m, and the fabric has a hand friction value in therange of less than 2.5.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fabric comprises one or morefibers having a denier per filament in the range of less than 5 g/9000m, e.g. 2 g/9000 m, and the fabric has a hand friction value in therange of less than 2.0, e.g. 1.85.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fabric comprises one or morefibers having a denier per filament in the range of less than 5 g/9000m, e.g. 2 g/9000 m, and the fabric has a stiffness value in the range ofless than 1.1.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fabric comprises one or morefibers having a denier per filament in the range of less than 5 g/9000m, e.g. 2 g/9000 m, and the fabric has a stiffness value in the range ofless than 1.0.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fabric comprises one or morefibers having a denier per filament in the range of less than 5 g/9000m, e.g. 2 g/9000 m, and the fabric has a stiffness value in the range ofless than 0.8.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fabric comprises one or morefibers having a denier per filament in the range of less than 5 g/9000m, e.g. 2 g/9000 m, and the fabric has a stiffness value in the range ofless than 0.7, e.g. 0.52.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fabric comprises one or morefibers having a denier per filament in the range of less than 5 g/9000m, e.g. 2 g/9000 m, and the fabric has a smoothness value in the rangeof less than 2, a wax value in the range of greater than 7, a handfriction value in the range of less than 3.5, and a stiffness value inthe range of less than 1.1.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fabric comprises one or morefibers having a denier per filament in the range of 5 to 7 g/9000 m,e.g. 6 g/9000 m, and the fabric has a smoothness value in the range ofless than 8.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fabric comprises one or morefibers having a denier per filament in the range of 5 to 7 g/9000 m,e.g. 6 g/9000 m, and the fabric has a smoothness value in the range ofless than 7, e.g. 5.30.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fabric comprises one or morefibers having a denier per filament in the range of 5 to 7 g/9000 m,e.g. 6 g/9000 m, and the fabric has a wax value in the range of greaterthan 8, e.g. 8.2.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fabric comprises one or morefibers having a denier per filament in the range of 5 to 7 g/9000 m,e.g. 6 g/9000 m, and the fabric has a hand friction value in the rangeof less than 7.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fabric comprises one or morefibers having a denier per filament in the range of 5 to 7 g/9000 m,e.g. 6 g/9000 m, and the fabric has a hand friction value in the rangeof less than 6.0.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fabric comprises one or morefibers having a denier per filament in the range of 5 to 7 g/9000 m,e.g. 6 g/9000 m, and the fabric has a stiffness value in the range ofless than 3.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fabric comprises one or morefibers having a denier per filament in the range of 5 to 7 g/9000 m,e.g. 6 g/9000 m, and the fabric has a stiffness value in the range ofless than 2.0.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fabric comprises one or morefibers having a denier per filament in the range of 5 to 7 g/9000 m,e.g. 6 g/9000 m, and the fabric has a stiffness value in the range ofless than 1.8.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fabric comprises one or morefibers having a denier per filament in the range of 5 to 7 g/9000 m,e.g. 6 g/9000 m, and the fabric has a smoothness value in the range ofless than 8, a wax value in the range of greater than 8, a hand frictionvalue in the range of less than 7, and a stiffness value in the range ofless than 3.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that said fabric is abraded.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that said fabric is abraded about lessthan 30 weight percent based on the weight of the fabric prior toabrasion.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that said fabric is abraded about lessthan 20 weight percent based on the weight of the fabric prior toabrasion.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that said fabric is abraded about lessthan 10 weight percent based on the weight of the fabric prior toabrasion.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that said fabric is abraded about lessthan 5 weight percent based on the weight of the fabric prior toabrasion.

In an alternative embodiment, the instant invention provides apolyethylene composition, method of producing the same, fibers madetherefrom, method of making such fibers, fabrics made from such fibers,and method of fabricating such fabrics, in accordance with any of thepreceding embodiments, except that the fabric is used as an articleselected from the group consisting of upholstery, apparel, wallcovering, carpet, diaper topsheet, diaper backsheet, medical fabric,surgical wrap, hospital gown, wipe, textile, and geotextile.

BRIEF DESCRIPTION OF THE DRAWINGS

For the purpose of illustrating the invention, there is shown in thedrawings a form that is exemplary; it being understood, however, thatthis invention is not limited to the precise arrangements andinstrumentalities shown.

FIG. 1 is a graph depicting the relationship between the Tenacity of theinventive fiber measured in g/denier and Melt Index (I₂) of theinventive polyethylene composition measured in g/10 minutes;

FIG. 2 is a graph depicting the relationship between the Tenacity of theinventive fiber measured in g/denier and Molecular Weight (M_(w)) of theinventive polyethylene composition measured in 10³ Daltons;

FIG. 3 is a graph depicting the relationship between the Elongation ofthe inventive fiber measured in percent and Melt Index (I₂) of theinventive polyethylene composition measured in g/10 minutes; and

FIG. 4 is a graph depicting the relationship between the Boiling WaterShrinkage of the annealed (An) at 120° C. and unannealed (Un) inventivefiber measured in percent and Density of the inventive polyethylenecomposition measured in g/cm³.

DETAILED DESCRIPTION OF THE INVENTION

The instant invention relates to polyethylene compositions, method ofproducing the same, fibers made therefrom, and method of making thesame. The polyethylene composition according to instant inventioncomprises: (a) less than or equal to 100 percent by weight of the unitsderived from ethylene; and (b) less than 20 percent by weight of unitsderived from one or more α-olefin comonomers. The polyethylenecomposition according to instant invention has a density in the range of0.920 to 0.970 g/cm³, a molecular weight distribution (M_(w)/M_(n)) inthe range of 1.70 to 3.5, a melt index (I₂) in the range of 0.2 to 1000g/10 minutes, a molecular weight distribution (M_(z)/M_(w)) in the rangeof less than 2.5, vinyl unsaturation of less than 0.1 vinyls per onethousand carbon atoms present in the backbone of the composition.

The polyethylene composition according to instant invention possessesunique properties and differentiated performance in differentapplications, as described in further details hereinbelow.

The term (co)polymerization, as used herein, refers to thepolymerization of ethylene and optionally one or more comonomers, e.g.one or more α-olefin comonomers. Thus, the term (co)polymerizationrefers to both polymerization of ethylene and copolymerization ofethylene and one or more comonomers, e.g. one or more α-olefincomonomers.

The polyethylene composition according to instant invention has adensity in the range of 0.920 to 0.970 g/cm³. All individual values andsubranges from 0.920 to 0.970 g/cm³ are included herein and disclosedherein; for example, the density can be from a lower limit of 0.920,0.923, 0.928, 0.930, 0.936, or 0.940 g/cm³ to an upper limit of 0.941,0.947, 0.954, 0.955, 0.959, 0.960, 0.965, 0.968, or 0.970 g/cm³. Forexample, the polyethylene composition may have a density in the range of0.920 to 0.965 g/cm³; or in the alternative, the polyethylenecomposition may have a density in the range of 0.920 to 0.960 g/cm³; orin the alternative, the polyethylene composition may have a density inthe range of 0.920 to 0.955 g/cm³; or in the alternative, thepolyethylene composition may have a density in the range of 0.920 to0.950 g/cm³; or in the alternative, the polyethylene composition mayhave a density in the range of 0.930 to 0.965 g/cm³; or in thealternative, the polyethylene composition may have a density in therange of 0.930 to 0.960 g/cm³; or in the alternative, the polyethylenecomposition may have a density in the range of 0.930 to 0.955 g/cm³; orin the alternative, the polyethylene composition may have a density inthe range of 0.930 to 0.950 g/cm³; or in the alternative, thepolyethylene composition may have a density in the range of 0.940 to0.965 g/cm³; or in the alternative, the polyethylene composition mayhave a density in the range of 0.940 to 0.960 g/cm³; or in thealternative, the polyethylene composition may have a density in therange of 0.940 to 0.955 g/cm³; or in the alternative, the polyethylenecomposition may have a density in the range of 0.940 to 0.950 g/cm³.

The polyethylene composition according to the instant invention has amolecular weight distribution (M_(w)/M_(n)) in the range of 1.70 to3.62. All individual values and subranges from 1.70 to 3.62 are includedherein and disclosed herein; for example, the molecular weightdistribution (M_(w)/M_(n)) can be from a lower limit of 1.70, 1.80,1.90, 2.10, 2.30, 2.50, 2.70, 2.90, 3.10, 3.30, or 3.50 to an upperlimit of 1.85, 1.95, 2.15, 2.35, 2.55, 2.75, 2.95, 3.15, 3.35, 3.50,3.55, 3.60, or 3.62. For example, the polyethylene composition may havea molecular weight distribution (M _(w)/M_(n)) in the range of 1.70 to3.60; or in the alternative, the polyethylene composition may have amolecular weight distribution (M_(w)/M_(n)) in the range of 1.70 to3.55; or in the alternative, the polyethylene composition may have amolecular weight distribution (M_(w)/M_(n)) in the range of 1.70 to3.50; or in the alternative, the polyethylene composition may have amolecular weight distribution (M_(w)/M_(n)) in the range of 1.70 to3.35; or in the alternative, the polyethylene composition may have amolecular weight distribution (M_(w)/M_(n)) in the range of 1.70 to3.15; or in the alternative, the polyethylene composition may have amolecular weight distribution (M_(w)/M_(n)) in the range of 1.70 to2.95; or in the alternative, the polyethylene composition may have amolecular weight distribution (M_(w)/M_(n)) in the range of 1.70 to2.75; or in the alternative, the polyethylene composition may have amolecular weight distribution (M_(w)/M_(n)) in the range of 1.70 to2.55; or in the alternative, the polyethylene composition may have amolecular weight distribution (M_(w)/M_(n)) in the range of 1.70 to2.35; or in the alternative, the polyethylene composition may have amolecular weight distribution (M_(w)/M_(n)) in the range of 1.70 to2.15; or in the alternative, the polyethylene composition may have amolecular weight distribution (M_(w)/M_(n)) in the range of 1.70 to1.95; or in the alternative, the polyethylene composition may have amolecular weight distribution (M_(w)/M_(n)) in the range of 1.70 to1.85.

The polyethylene composition according to the instant invention has amelt index (I₂) in the range of 0.1 to 1000 g/10 minutes. All individualvalues and subranges from 0.1 to 1000 g/10 minutes are included hereinand disclosed herein; for example, the melt index (I₂) can be from alower limit of 0.1, 0.2, 0.5, 1, 2, 3, 5, 10, 20, 30, 40, 60, 80, or 100g/10 minutes, to an upper limit of 5, 10, 30, 35, 50, 80, 90, 100, 110,150, 200, 220, 250, 300, 500, 800, or 1000 g/10 minutes. For example,the polyethylene composition may have a melt index (I₂) in the range of1 to 150 g/10 minutes; or in the alternative, the polyethylenecomposition may have a melt index (I₂) in the range of 1 to 50 g/10minutes; or in the alternative, the polyethylene composition may have amelt index (I₂) in the range of 1 to 35 g/10 minutes; or in thealternative, the polyethylene composition may have a melt index (I₂) inthe range of 1 to 30 g/10 minutes; or in the alternative, thepolyethylene composition may have a melt index (I₂) in the range of 1 to20 g/10 minutes; or in the alternative, the polyethylene composition mayhave a melt index (I₂) in the range of 1 to 10 g/10 minutes; or in thealternative, the polyethylene composition may have a melt index (I₂) inthe range of 3 to 150 g/10 minutes; or in the alternative, thepolyethylene composition may have a melt index (I₂) in the range of 3 to50 g/10 minutes; or in the alternative, the polyethylene composition mayhave a melt index (I₂) in the range of 3 to 35 g/10 minutes; or in thealternative, the polyethylene composition may have a melt index (I₂) inthe range of 3 to 30 g/10 minutes; or in the alternative, thepolyethylene composition may have a melt index (I₂) in the range of 3 to20 g/10 minutes; or in the alternative, the polyethylene composition mayhave a melt index (I₂) in the range of 3 to 10 g/10 minutes.

The polyethylene composition according to the instant invention has amelt flow rate (I₂₁) in the range of 2 to 20,000 g/10 minutes. Allindividual values and subranges from 2 to 20,000 g/10 minutes areincluded herein and disclosed herein; for example, the melt flow rate(I₂₁) can be from a lower limit of 3.4, 4.3, 6.0, 10, 20, 50, 100, 150,300,or 500 g/10 minutes, to an upper limit of 20,000, 15,000, 10,000,5,000, 1,200, 1,000, 800, 700, 600, 500, 400, 300, 250, 200, 100, 80,70, or 50 g/10 minutes. For example, the polyethylene composition mayhave a melt flow rate (I₂₁) in the range of 3.4 to 1200 g/10 minutes; orin the alternative, the polyethylene composition may have a melt flowrate (I₂₁) in the range of 3.4 to 1,000 g/10 minutes; or in thealternative, the polyethylene composition may have a melt flow rate(I₂₁) in the range of 3.4 to 500 g/10 minutes; or in the alternative,the polyethylene composition may have a melt flow rate (I₂₁) in therange of 3.4 to 400 g/10 minutes; or in the alternative, thepolyethylene composition may have a melt flow rate (I₂₁) in the range of3.4 to 300 g/10 minutes; or in the alternative, the polyethylenecomposition may have a melt flow rate (I₂₁) in the range of 3.4 to 250g/10 minutes.

The polyethylene composition according to the instant invention has amelt flow ratio (I₂₁/I₂) in the range of 17 to 24. All individual valuesand subranges from 17 to 24 minutes are included herein and disclosedherein; for example, the melt flow ratio (I₂₁/I₂) can be from a lowerlimit of 17, 17.5, 18, 18.5, 19, 19.5, 20, 20.5, 21, 21.5, 22, 22.5, or23.5 to an upper limit of 18, 18.5, 19, 19.5, 20, 20.5, 21, 21.5, 22,22.5, 23.5 or 24. For example, the polyethylene composition may have amelt flow ratio (I₂₁/I₂) in the range 17 to 23; or in the alternative,the polyethylene composition may have a melt flow ratio (I₂₁/I₂) in therange 17 to 22; or in the alternative, the polyethylene composition mayhave a melt flow ratio (I₂₁/I₂) in the range 18 to 24; or in thealternative, the polyethylene composition may have a melt flow ratio(I₂₁/I₂) in the range 18 to 23; or in the alternative, the polyethylenecomposition may have a melt flow ratio (I₂₁/I₂) in the range 19 to 24;or in the alternative, the polyethylene composition may have a melt flowratio (I₂₁/I₂) in the range 19 to 23; or in the alternative, thepolyethylene composition may have a melt flow ratio (I₂₁/I₂) in therange 21 to 24; or in the alternative, the polyethylene composition mayhave a melt flow ratio (I₂₁/I₂) in the range 21 to 23.

The polyethylene composition according to the instant invention has amolecular weight (M_(w)) in the range of 15,000 to 150,000 daltons. Allindividual values and subranges from 15,000 to 150,000 daltons areincluded herein and disclosed herein; for example, the molecular weight(M_(w)) can be from a lower limit of 15,000, 20,000, 25,000, 30,000,34,000, 40,000, 50,000, 60,000, 70,000, 80,000, 90,000, 95,000, or100,000 daltons to an upper limit of 20,000, 25,000, 30,000, 33,000,40,000, 50,000, 60,000, 70,000, 80,000, 90,000, 95,000, 100,000,115,000, 125,000, or 150,000. For example, the polyethylene compositionmay have a molecular weight (M_(w)) in the range of 15,000 to 125,000daltons; or in the alternative, the polyethylene composition may have amolecular weight (M_(w)) in the range of 15,000 to 115,000 daltons; orin the alternative, the polyethylene composition may have a molecularweight (M_(w)) in the range of 15,000 to 100,000 daltons; or in thealternative, the polyethylene composition may have a molecular weight(M_(w)) in the range of 20,000 to 150,000 daltons; or in thealternative, the polyethylene composition may have a molecular weight(M_(w)) in the range of 30,000 to 150,000 daltons; or in thealternative, the polyethylene composition may have a molecular weight(M_(w)) in the range of 40,000 to 150,000 daltons; or in thealternative, the polyethylene composition may have a molecular weight(M_(w)) in the range of 50,000 to 150,000 daltons; or in thealternative, the polyethylene composition may have a molecular weight(M_(w)) in the range of 60,000 to 150,000 daltons; or in thealternative, the polyethylene composition may have a molecular weight(M_(w)) in the range of 80,000 to 150,000 daltons.

The polyethylene composition may have molecular weight distribution(M_(z)/M_(w)) in the range of less than 5. All individual values andsubranges from less than 5 are included herein and disclosed herein; forexample, the polyethylene composition may have a molecular weightdistribution (M_(z)/M_(w)) in the range of less than 4.5; or in thealternative, the polyethylene composition may have a molecular weightdistribution (M_(z)/M_(w)) in the range of less than 4; or in thealternative, the polyethylene composition may have a molecular weightdistribution (M_(z)/M_(w)) in the range of less than 3.5; or in thealternative, the polyethylene composition may have a molecular weightdistribution (M_(z)/M_(w)) in the range of less than 3.0; or in thealternative, the polyethylene composition may have a molecular weightdistribution (M_(z)/M_(w)) in the range of less than 2.8; or in thealternative, the polyethylene composition may have a molecular weightdistribution (M_(z)/M_(w)) in the range of less than 2.6; or in thealternative, the polyethylene composition may have a molecular weightdistribution (M_(z)/M_(w)) in the range of less than 2.5; or in thealternative, the polyethylene composition may have a molecular weightdistribution (M_(z)/M_(w)) in the range of less than 2.4; or in thealternative, the polyethylene composition may have a molecular weightdistribution (M_(z)/M_(w)) in the range of less than 2.3; or in thealternative, the polyethylene composition may have a molecular weightdistribution (M_(z)/M_(w)) in the range of less than 2.2.

The polyethylene composition may have a vinyl unsaturation of less than0.1 vinyls per one thousand carbon atoms present in the backbone of thepolyethylene composition. All individual values and subranges from lessthan 0.1 are included herein and disclosed herein; for example, thepolyethylene composition may have a vinyl unsaturation of less than 0.08vinyls per one thousand carbon atoms present in the backbone of thepolyethylene composition; or in the alternative, the polyethylenecomposition may have a vinyl unsaturation of less than 0.06 vinyls perone thousand carbon atoms present in the backbone of the polyethylenecomposition; or in the alternative, the polyethylene composition mayhave a vinyl unsaturation of less than 0.04 vinyls per one thousandcarbon atoms present in the backbone of the polyethylene composition; orin the alternative, the polyethylene composition may have a vinylunsaturation of less than 0.02 vinyls per one thousand carbon atomspresent in the backbone of the polyethylene composition; or in thealternative, the polyethylene composition may have a vinyl unsaturationof less than 0.01 vinyls per one thousand carbon atoms present in thebackbone of the polyethylene composition; or in the alternative, thepolyethylene composition may have a vinyl unsaturation of less than0.001 vinyls per one thousand carbon atoms present in the backbone ofthe polyethylene composition.

The polyethylene composition may comprise less than 25 percent by weightof units derived from one or more α-olefin comonomers. All individualvalues and subranges from less than 25 weight percent are includedherein and disclosed herein; for example, the polyethylene compositionmay comprise less than 20 percent by weight of units derived from one ormore α-olefin comonomers; or in the alternative, the polyethylenecomposition may comprise less than 15 percent by weight of units derivedfrom one or more α-olefin comonomers; or in the alternative, thepolyethylene composition may comprise less than 12 percent by weight ofunits derived from one or more α-olefin comonomers; or in thealternative, the polyethylene composition may comprise less than 11percent by weight of units derived from one or more α-olefin comonomers;or in the alternative, the polyethylene composition may comprise lessthan 9 percent by weight of units derived from one or more α-olefincomonomers; or in the alternative, the polyethylene composition maycomprise less than 7 percent by weight of units derived from one or moreα-olefin comonomers; or in the alternative, the polyethylene compositionmay comprise less than 5 percent by weight of units derived from one ormore α-olefin comonomers; or in the alternative, the polyethylenecomposition may comprise less than 3 percent by weight of units derivedfrom one or more α-olefin comonomers; or in the alternative, thepolyethylene composition may comprise less than 1 percent by weight ofunits derived from one or more α-olefin comonomers; or in thealternative, the polyethylene composition may comprise less than 0.5percent by weight of units derived from one or more α-olefin comonomers.

The α-olefin comonomers typically have no more than 20 carbon atoms. Forexample, the α-olefin comonomers may preferably have 3 to 10 carbonatoms, and more preferably 3 to 8 carbon atoms. Exemplary α-olefincomonomers include, but are not limited to, propylene, 1-butene,1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, and4-methyl-1-pentene. The one or more α-olefin comonomers may, forexample, be selected from the group consisting of propylene, 1-butene,1-hexene, and 1-octene; or in the alternative, from the group consistingof 1-hexene and 1-octene.

The polyethylene composition may comprise at least 75 percent by weightof units derived from ethylene. All individual values and subranges fromat least 75 weight percent are included herein and disclosed herein; thepolyethylene composition may comprise at least 80 percent by weight ofunits derived from ethylene; or in the alternative, for example, thepolyethylene composition may comprise at least 85 percent by weight ofunits derived from ethylene; or in the alternative, the polyethylenecomposition may comprise at least 88 percent by weight of units derivedfrom ethylene; or in the alternative, the polyethylene composition maycomprise at least 89 percent by weight of units derived from ethylene;or in the alternative, the polyethylene composition may comprise atleast 91 percent by weight of units derived from ethylene; or in thealternative, the polyethylene composition may comprise at least 93percent by weight of units derived from ethylene; or in the alternative,the polyethylene composition may comprise at least 95 percent by weightof units derived from ethylene; or in the alternative, the polyethylenecomposition may comprise at least 97 percent by weight of units derivedfrom ethylene; or in the alternative, the polyethylene composition maycomprise at least 99 percent by weight of units derived from ethylene;or in the alternative, the polyethylene composition may comprise atleast 99.5 percent by weight of units derived from ethylene.

The polyethylene composition of the instant invention is substantiallyfree of any long chain branching, and preferably, the polyethylenecomposition of the instant invention is free of any long chainbranching. Substantially free of any long chain branching, as usedherein, refers to a polyethylene composition preferably substituted withless than about 0.1 long chain branching per 1000 total carbons, andmore preferably, less than about 0.01 long chain branching per 1000total carbons. In the alternative, the polyethylene composition of theinstant invention is free of any long chain branching.

The polyethylene composition may have a short chain branchingdistribution breadth (SCBDB) in the range of 2 to 40° C. All individualvalues and subranges from 2 to 40° C. are included herein and disclosedherein; for example, the short chain branching distribution breadth(SCBDB) can be from a lower limit of 2, 3, 4, 5, 6, 8, 10, 12, 15, 18,20, 25, or 30° C. to an upper limit of 40, 35, 30, 29, 27, 25, 22, 20,15, 12, 10, 8, 6, 4, or 3° C. For example, the polyethylene compositionmay have a short chain branching distribution breadth (SCBDB) in therange of 2 to 35° C. ; or in the alternative, the polyethylenecomposition may have a short chain branching distribution breadth(SCBDB) in the range of 2 to 30° C.; or in the alternative, thepolyethylene composition may have a short chain branching distributionbreadth (SCBDB) in the range of 2 to 25° C.; or in the alternative, thepolyethylene composition may have a short chain branching distributionbreadth (SCBDB) in the range of 2 to 20° C.; or in the alternative, thepolyethylene composition may have a short chain branching distributionbreadth (SCBDB) in the range of 2 to 15° C.; or in the alternative, thepolyethylene composition may have a short chain branching distributionbreadth (SCBDB) in the range of 2 to 10° C.; or in the alternative, thepolyethylene composition may have a short chain branching distributionbreadth (SCBDB) in the range of 2 to 5° C.; or in the alternative, thepolyethylene composition may have a short chain branching distributionbreadth (SCBDB) in the range of 4 to 35° C.; or in the alternative, thepolyethylene composition may have a short chain branching distributionbreadth (SCBDB) in the range of 4 to 30° C.; or in the alternative, thepolyethylene composition may have a short chain branching distributionbreadth (SCBDB) in the range of 4 to 25° C.; or in the alternative, thepolyethylene composition may have a short chain branching distributionbreadth (SCBDB) in the range of 4 to 20° C.; or in the alternative, thepolyethylene composition may have a short chain branching distributionbreadth (SCBDB) in the range of 4 to 15° C.; or in the alternative, thepolyethylene composition may have a short chain branching distributionbreadth (SCBDB) in the range of 4 to 10° C.; or in the alternative, thepolyethylene composition may have a short chain branching distributionbreadth (SCBDB) in the range of 4 to 5° C. In the alternative, thepolyethylene composition may have a short chain branching distributionbreadth (SCBDB) in the range less than ((0.0312)(melt index (I₂)+2.87)°C.

The inventive polyethylene composition may have a shear viscosity in therange of 20 to 250 Pascal-s at 3000s⁻¹ shear rate measured at 190° C.All individual values and subranges from 20 to 250 Pascal-s at 3000s⁻¹shear rate measured at 190° C. are included herein and disclosed herein;for example, the polyethylene composition may have a shear viscosity inthe range of 20 to 200 Pascal-s at 3000s⁻¹ shear rate measured at 190°C.; or in the alternative, the polyethylene composition may have a shearviscosity in the range of 20 to 150 Pascal-s at 3000s⁻¹ shear ratemeasured at 190° C.; or in the alternative, the polyethylene compositionmay have a shear viscosity in the range of 20 to 130 Pascal-s at 3000s⁻¹shear rate measured at 190° C.; or in the alternative, the polyethylenecomposition may have a shear viscosity in the range of 25 to 150Pascal-s at 3000s⁻¹ shear rate measured at 190° C.; or in thealternative, the polyethylene composition may have a shear viscosity inthe range of 25 to 80 Pascal-s at 3000s⁻¹ shear rate measured at 190°C.; or in the alternative, the polyethylene composition may have a shearviscosity in the range of 25 to 55 Pascal-s at 3000s⁻¹ shear ratemeasured at 190° C.; or in the alternative, the polyethylene compositionmay have a shear viscosity in the range of 25 to 50 Pascal-s at 3000s⁻¹shear rate measured at 190° C.; or in the alternative, the polyethylenecomposition may have a shear viscosity in the range of 25 to 45 Pascal-sat 3000s⁻¹ shear rate measured at 190° C.; or in the alternative, thepolyethylene composition may have a shear viscosity in the range of 25to 45 Pascal-s at 3000s⁻¹ shear rate measured at 190° C.; or in thealternative, the polyethylene composition may have a shear viscosity inthe range of 25 to 35 Pascal-s at 3000s⁻¹ shear rate measured at 190°C.; or in the alternative, the polyethylene composition may have a shearviscosity in the range of 25 to 30 Pascal-s at 3000s⁻¹ shear ratemeasured at 190° C.; or in the alternative, the polyethylene compositionmay have a shear viscosity in the range of 30 to 55 Pascal-s at 3000s⁻¹shear rate measured at 190° C.; or in the alternative, the polyethylenecomposition may have a shear viscosity in the range of 35 to 55 Pascal-sat 3000s⁻¹ shear rate measured at 190° C.; or in the alternative, thepolyethylene composition may have a shear viscosity in the range of 40to 55 Pascal-s at 3000s⁻¹ shear rate measured at 190° C.; or in thealternative, the polyethylene composition may have a shear viscosity inthe range of 45 to 55 Pascal-s at 3000s⁻¹ shear rate measured at 190°C.; or in the alternative, the polyethylene composition may have a shearviscosity in the range of 50 to 55 Pascal-s at 3000s⁻¹ shear ratemeasured at 190° C.

The inventive polyethylene composition may further comprise less than orequal to 100 parts by weight of hafnium residues remaining from thehafnium based metallocene catalyst per one million parts of polyethylenecomposition. All individual values and subranges from less than or equalto 100 ppm are included herein and disclosed herein; for example, thepolyethylene composition may further comprise less than or equal to 10parts by weight of hafnium residues remaining from the hafnium basedmetallocene catalyst per one million parts of polyethylene composition;or in the alternative, the polyethylene composition may further compriseless than or equal to 8 parts by weight of hafnium residues remainingfrom the hafnium based metallocene catalyst per one million parts ofpolyethylene composition; or in the alternative, the polyethylenecomposition may further comprise less than or equal to 6 parts by weightof hafnium residues remaining from the hafnium based metallocenecatalyst per one million parts of polyethylene composition; or in thealternative, the polyethylene composition may further comprise less thanor equal to 4 parts by weight of hafnium residues remaining from thehafnium based metallocene catalyst per one million parts of polyethylenecomposition; or in the alternative, the polyethylene composition mayfurther comprise less than or equal to 2 parts by weight of hafniumresidues remaining from the hafnium based metallocene catalyst per onemillion parts of polyethylene composition; or in the alternative, thepolyethylene composition may further comprise less than or equal to 1.5parts by weight of hafnium residues remaining from the hafnium basedmetallocene catalyst per one million parts of polyethylene composition;or in the alternative, the polyethylene composition may further compriseless than or equal to 1 parts by weight of hafnium residues remainingfrom the hafnium based metallocene catalyst per one million parts ofpolyethylene composition; or in the alternative, the polyethylenecomposition may further comprise less than or equal to 0.75 parts byweight of hafnium residues remaining from the hafnium based metallocenecatalyst per one million parts of polyethylene composition; or in thealternative, the polyethylene composition may further comprise less thanor equal to 0.5 parts by weight of hafnium residues remaining from thehafnium based metallocene catalyst per one million parts of polyethylenecomposition the polyethylene composition may further comprise from 0.1to 100 parts by weight of hafnium residues remaining from the hafniumbased metallocene catalyst per one million parts of polyethylenecomposition. The hafnium residues remaining from the hafnium basedmetallocene catalyst in the inventive polyethylene composition may bemeasured by x-ray fluorescence (XRF), which is calibrated to referencestandards. The polymer resin granules were compression molded atelevated temperature into plaques having a thickness of about ⅜ of aninch for the x-ray measurement in a preferred method. At very lowconcentrations of metal, such as below 0.1 ppm, ICP-AES would be asuitable method to determine metal residues present in the inventivepolyethylene composition. In one embodiment, the inventive polyethylenecomposition has substantially no chromium, zirconium or titaniumcontent, that is, no or only what would be considered by those skilledin the art, trace amounts of these metals are present, such as, forexample, less than 0.001 ppm.

The inventive polyethylene composition in accordance with the instantinvention may have less than 2 peaks on an elution temperature-elutedamount curve determined by continuous temperature rising elutionfraction method at equal or above 30° C., wherein the purge peak whichis below 30° C. is excluded. In the alternative, the polyethylenecomposition may have only 1 peak or less on an elutiontemperature-eluted amount curve determined by continuous temperaturerising elution fraction method at equal or above 30° C., wherein thepurge peak which is below 30° C. is excluded. In the alternative, thepolyethylene composition may have only 1 peak on an elutiontemperature-eluted amount curve determined by continuous temperaturerising elution fraction method at equal or above 30° C., wherein thepurge peak which is below 30° C. is excluded. In addition, artifactsgenerated due to instrumental noise at either side of a peak are notconsidered to be peaks.

The inventive polyethylene composition may further comprise additionalcomponents such as one or more other polymers and/or one or moreadditives. Such additives include, but are not limited to, antistaticagents, color enhancers, dyes, lubricants, fillers, pigments, primaryantioxidants, secondary antioxidants, processing aids, UV stabilizers,anti-blocks, slip agents, tackifiers, fire retardants, anti-microbialagents, odor reducer agents, anti fungal agents, and combinationsthereof. The inventive polyethylene composition may contain any amountsof additives. The inventive polyethylene composition may comprise fromabout 0.1 to about 10 percent by the combined weight of such additives,based on the weight of the inventive polyethylene composition includingsuch additives. All individual values and subranges from about 0.1 toabout 10 weight percent are included herein and disclosed herein; forexample, the inventive polyethylene composition may comprise from 0.1 to7 percent by the combined weight of additives, based on the weight ofthe inventive polyethylene composition including such additives; in thealternative, the inventive polyethylene composition may comprise from0.1 to 5 percent by the combined weight of additives, based on theweight of the inventive polyethylene composition including suchadditives; or in the alternative, the inventive polyethylene compositionmay comprise from 0.1 to 3 percent by the combined weight of additives,based on the weight of the inventive polyethylene composition includingsuch additives; or in the alternative, the inventive polyethylenecomposition may comprise from 0.1 to 2 percent by the combined weight ofadditives, based on the weight of the inventive polyethylene compositionincluding such additives; or in the alternative, the inventivepolyethylene composition may comprise from 0.1 to 1 percent by thecombined weight of additives, based on the weight of the inventivepolyethylene composition including such additives; or in thealternative, the inventive polyethylene composition may comprise from0.1 to 0.5 percent by the combined weight of additives, based on theweight of the inventive polyethylene composition including suchadditives. Antioxidants, such as Irgafos™ 168, Irganox™ 3114, Cyanox™1790, Irganox™ 1010, Irganox™ 1076, Irganox™1330, Irganox™ 1425WL,Irgastab™ may be used to protect the inventive polyethylene compositionfrom thermal and/or oxidative degradation. Irganox™ 1010 istetrakis(methylene(3,5-di-tert-butyl-4hydroxyhydrocinnamate),commercially available from Ciba Geigy Inc.; Irgafos™ 168 is tris(2,4di-tert-butylphenyl)phosphite, commercially available from Ciba GeigyInc.; Irganox™ 3114 is[1,3,5-Tris(3,5-di-(tert)-butyl-4-hydroxybenzyl)-1,3,5-triazine-2,4,6(1H,3H,5H)-trione],commercially available from Ciba Geigy Inc.; Irganox™ 1076 is (Octadecyl3,5-di-tert-butyl-4 hydroxycinnamate), commercially available from CibaGeigy Inc.; Irganox™1330 is[1,3,5-Trimethyl-2,4,6-tris(3,5-di-tert-butyl-4-hydroxybenzyl)benzene],commercially available from Ciba Geigy Inc.; Irganox™1425WL is (Calciumbis[fluoriding(3,5-di-(tert)-butyl-4-hydroxybenzyl)phosphonate]),commercially available from Ciba Geigy Inc.; Irgastab™ is[bis(hydrogenated tallow alkyl)amines, oxidized], commercially availablefrom Ciba Geigy Inc.; Cyanox™ 1790 is[Tris(4-t-butyl-3-hydroxy-2,6-dimethylbenzyl)-s-triazine-2,4,6-(1H,3H,5H)-trione],commercially available from Cytec Industries, Inc. Other commerciallyavailable antioxidants include, but are not limited to, Ultranox™ 626, aBis(2,4-di-t-butylphenyl) Pentaerythritol Diphosphite, commerciallyavailable from Chemtura Corporation; P-EPQ™, a Phosphonous acid,P,P′-[[1,1′-biphenyl]-4,4′-diyl]bis-,P,P,P′,P′-tetrakis[2,4-bis(1,1-dimethylethyl)phenyl]ester,commercially available from Clariant Corporation; Doverphos™ 9228, aBis(2,4-decumylphenyl) Pentaerythritol Diphosphite, commerciallyavailable from Dover Chemical Corporation; Chimassorb™ 944, aPoly[[6-[(1,1,3,3-tetramethylbutyl)amino]-1,3,5-triazine-2,4-diyl][(2,2,6,6-tetramethyl-4-piperidinyl)imino]-1,6-hexanediyl[(2,2,6,6-tetramethyl-4-piperidinyl)imino]],commercially available from Ciba Geigy Inc.; Chimassorb™ 119, a1,3,5-Triazine-2,4,6-triamine,N2,N2′-1,2-ethanediylbis[N2-[3-[[4,6-bis[butyl(1,2,2,6,6-pentamethyl-4-piperidinyl)amino]-1,3,5-triazin-2-yl]amino]propyl]-N4,N6-dibutyl-N4,N6-bis(1,2,2,6,6-pentamethyl-4-piperidinyl)-,commercially available from Ciba Geigy Inc.; Chimassorb™ 2020, aPoly[[6-[butyl(2,2,6,6-tetramethyl-4-piperidinyl)amino]-1,3,5-triazine-2,4-diyl][(2,2,6,6-tetramethyl-4-piperidinyl)imino]-1,6-hexanediyl[(2,2,6,6-tetramethyl-4-piperidinyl)imino]],α-[[6-[[4,6-bis(dibutylamino)-1,3,5-triazin-2-yl](2,2,6,6-tetramethyl-4-piperidinyl)amino]hexyl](2,2,6,6-tetramethyl-4-piperidinyl)amino]-ω-[4,6-bis(dibutylamino)-1,3,5-triazin-2-yl]-,commercially available from Ciba Geigy Inc.; Tinuvin™ 622, a Butanedioicacid polymer with 4-hydroxy-2,2,6,6-tetramethyl-1-piperidineethanol,commercially available from Ciba Geigy Inc.; Tinuvin™ 770, a Decanedioicacid, 1,10-bis(2,2,6,6-tetramethyl-4-piperidinyl) ester, commerciallyavailable from Ciba Geigy Inc.; Uvasorb HA™ 88, a 2,5-Pyrrolidinedione,3-dodecyl-1-(2,2,6,6-tetramethyl-4-piperidinyl), commercially availablefrom 3V; CYASORB™ UV-3346, aPoly[[6-(4-morpholinyl)-1,3,5-triazine-2,4-diyl][(2,2,6,6-tetramethyl-4-piperidinyl)imino]-1,6-hexanediyl[(2,2,6,6-tetramethyl-4-piperidinyl)imino]],commercially available from Cytec Industries, Inc.; CYASORB™ UV-3529, aPoly[[6-(4-morpholinyl)-1,3,5-triazine-2,4-diyl][(1,2,2,6,6-pentamethyl-4-piperidinyl)imino]-1,6-hexanediyl[(1,2,2,6,6-pentamethyl-4-piperidinyl)imino]],commercially available from Cytec Industries, Inc.; and Hostavin™ N 30,a 7-Oxa-3,20-iazadispiro[5.1.11.2]heneicosan-21-one,2,2,4,4-tetramethyl-20-(2-oxiranylmethyl)-, polymer with2-(chloromethyl)oxirane, commercially available from ClariantCorporation.

Any conventional ethylene (co)polymerization reaction processes may beemployed to produce the inventive polyethylene composition. Suchconventional ethylene (co)polymerization reaction processes include, butare not limited to, gas phase polymerization process, slurry phasepolymerization process, liquid phase polymerization process, andcombinations thereof using one or more conventional reactors, e.g.fluidized bed gas phase reactors, loop reactors, stirred tank reactors,batch reactors in parallel, series, and/or any combinations thereof. Inthe alternative, the inventive polyethylene composition may be producedin a high pressure reactor via a coordination catalyst system. Forexample, the inventive polyethylene composition may be produced via gasphase polymerization process in a single gas phase reactor; however, theinstant invention is not so limited, and any of the above polymerizationprocesses may be employed. In one embodiment, the polymerization reactormay comprise of two or more reactors in series, parallel, orcombinations thereof. Preferably, the polymerization reactor is a singlereactor, e.g. a fluidized bed gas phase reactor. In another embodiment,the gas phase polymerization reactor is a continuous polymerizationreactor comprising one or more feed streams. In the polymerizationreactor, the one or more feed streams are combined together, and the gascomprising ethylene and optionally one or more comonomers, e.g. one ormore α-olefins, are flowed or cycled continuously through thepolymerization reactor by any suitable means. The gas comprisingethylene and optionally one or more comonomers, e.g. one or moreα-olefins, may be fed up through a distributor plate to fluidize the bedin a continuous fluidization process.

In production, a hafnium based metallocene catalyst system including acocatalyst, as described hereinbelow in further details, ethylene,optionally one or more alpha-olefin comonomers, hydrogen, optionally oneor more inert gases and/or liquids, e.g. N₂, isopentane, and hexane, andoptionally one or more continuity additive, e.g. ethoxylated stearylamine or aluminum distearate or combinations thereof, are continuouslyfed into a reactor, e.g. a fluidized bed gas phase reactor. The reactormay be in fluid communication with one or more discharge tanks, surgetanks, purge tanks, and/or recycle compressors. The temperature in thereactor is typically in the range of 70 to 115° C., preferably 75 to110° C., more preferably 75 to 100° C., and the pressure is in the rangeof 15 to 30 atm, preferably 17 to 26 atm. A distributor plate at thebottom of the polymer bed provides a uniform flow of the upflowingmonomer, comonomer, and inert gases stream. A mechanical agitator mayalso be provided to facilitate contact between the solid particles andthe comonomer gas stream. The fluidized bed, a vertical cylindricalreactor, may have a bulb shape at the top to facilitate the reduction ofgas velocity; thus, permitting the granular polymer to separate from theupflowing gases. The unreacted gases are then cooled to remove the heatof polymerization, recompressed, and then recycled to the bottom of thereactor. Once resin is removed from the reactor, it is transported to apurge bin to purge the residual hydrocarbons. Moisture may be introducedto react with residual catalyst and co-catalyst prior to exposure andreaction with oxygen. The inventive polyethylene composition may then betransferred to an extruder to be pelletized. Such pelletizationtechniques are generally known. The inventive polyethylene compositionmay further be melt screened. Subsequent to the melting process in theextruder, the molten composition is passed through one or more activescreens, positioned in series of more than one, with each active screenhaving a micron retention size of from about 2 μm to about 400 μm (2 to4×10⁻⁵ m), and preferably about 2 μm to about 300 μm (2 to 3×10⁻⁵ m),and most preferably about 2 μm to about 70 μm (2 to 7×10⁻⁶ m), at a massflux of about 5 to about 100 lb/hr/in² (1.0 to about 20 kg/s/m²). Suchfurther melt screening is disclosed in U.S. Pat. No. 6,485,662, which isincorporated herein by reference to the extent that it discloses meltscreening.

In an embodiment of a fluidized bed reactor, a monomer stream is passedto a polymerization section. The fluidized bed reactor may include areaction zone in fluid communication with a velocity reduction zone. Thereaction zone includes a bed of growing polymer particles, formedpolymer particles and catalyst composition particles fluidized by thecontinuous flow of polymerizable and modifying gaseous components in theform of make-up feed and recycle fluid through the reaction zone.Preferably, the make-up feed includes polymerizable monomer, mostpreferably ethylene and optionally one or more α-olefin comonomers, andmay also include condensing agents as is known in the art and disclosedin, for example, U.S. Pat. No. 4,543,399, U.S. Pat. No. 5,405,922, andU.S. Pat. No. 5,462,999.

The fluidized bed has the general appearance of a dense mass ofindividually moving particles, preferably polyethylene particles, ascreated by the percolation of gas through the bed. The pressure dropthrough the bed is equal to or slightly greater than the weight of thebed divided by the cross-sectional area. It is thus dependent on thegeometry of the reactor. To maintain a viable fluidized bed in thereaction zone, the superficial gas velocity through the bed must exceedthe minimum flow required for fluidization. Preferably, the superficialgas velocity is at least two times the minimum flow velocity.Ordinarily, the superficial gas velocity does not exceed 1.5 m/sec andusually no more than 0.76 m/sec is sufficient.

In general, the height to diameter ratio of the reaction zone can varyin the range of about 2:1 to about 5:1. The range, of course, can varyto larger or smaller ratios and depends upon the desired productioncapacity. The cross-sectional area of the velocity reduction zone istypically within the range of about 2 to about 3 multiplied by thecross-sectional area of the reaction zone.

The velocity reduction zone has a larger inner diameter than thereaction zone, and can be conically tapered in shape. As the namesuggests, the velocity reduction zone slows the velocity of the gas dueto the increased cross sectional area. This reduction in gas velocitydrops the entrained particles into the bed, reducing the quantity ofentrained particles that flow from the reactor. The gas exiting theoverhead of the reactor is the recycle gas stream.

The recycle stream is compressed in a compressor and then passed througha heat exchange zone where heat is removed before the stream is returnedto the bed. The heat exchange zone is typically a heat exchanger, whichcan be of the horizontal or vertical type. If desired, several heatexchangers can be employed to lower the temperature of the cycle gasstream in stages. It is also possible to locate the compressordownstream from the heat exchanger or at an intermediate point betweenseveral heat exchangers. After cooling, the recycle stream is returnedto the reactor through a recycle inlet line. The cooled recycle streamabsorbs the heat of reaction generated by the polymerization reaction.

Preferably, the recycle stream is returned to the reactor and to thefluidized bed through a gas distributor plate. A gas deflector ispreferably installed at the inlet to the reactor to prevent containedpolymer particles from settling out and agglomerating into a solid massand to prevent liquid accumulation at the bottom of the reactor as wellto facilitate easy transitions between processes that contain liquid inthe cycle gas stream and those that do not and vice versa. Suchdeflectors are described in the U.S. Pat. No. 4,933,149 and U.S. Pat.No. 6,627,713.

The hafnium based catalyst system used in the fluidized bed ispreferably stored for service in a reservoir under a blanket of a gas,which is inert to the stored material, such as nitrogen or argon. Thehafnium based catalyst system is injected into the bed at a point abovedistributor plate. Preferably, the hafnium based catalyst system isinjected at a point in the bed where good mixing with polymer particlesoccurs. Injecting the hafnium based catalyst system at a point above thedistribution plate facilitates the operation of a fluidized bedpolymerization reactor.

The monomers can be introduced into the polymerization zone in variousways including, but not limited to, direct injection through a nozzleinto the bed or cycle gas line. The monomers can also be sprayed ontothe top of the bed through a nozzle positioned above the bed, which mayaid in eliminating some carryover of fines by the cycle gas stream.

Make-up fluid may be fed to the bed through a separate line to thereactor. A gas analyzer determines the composition of the recyclestream, and the composition of the make-up stream is adjustedaccordingly to maintain an essentially steady state gaseous compositionwithin the reaction zone. The gas analyzer can be a conventional gasanalyzer that determines the recycle stream composition to maintain theratios of feed stream components. Such equipment is commerciallyavailable from a wide variety of sources. The gas analyzer is typicallypositioned to receive gas from a sampling point located between thevelocity reduction zone and heat exchanger.

The production rate of inventive polyethylene composition may beconveniently controlled by adjusting the rate of catalyst compositioninjection, monomer concentration, or both. Since any change in the rateof catalyst composition injection will change the reaction rate and thusthe rate at which heat is generated in the bed, the temperature of therecycle stream entering the reactor is adjusted to accommodate anychange in the rate of heat generation. This ensures the maintenance ofan essentially constant temperature in the bed. Complete instrumentationof both the fluidized bed and the recycle stream cooling system is, ofcourse, useful to detect any temperature change in the bed so as toenable either the operator or a conventional automatic control system tomake a suitable adjustment in the temperature of the recycle stream.

Under a given set of operating conditions, the fluidized bed ismaintained at essentially a constant height by withdrawing a portion ofthe bed as product at the rate of formation of the particulate polymerproduct. Since the rate of heat generation is directly related to therate of product formation, a measurement of the temperature rise of thefluid across the reactor, i.e. the difference between inlet fluidtemperature and exit fluid temperature, is indicative of the rate ofinventive polyethylene composition formation at a constant fluidvelocity if no or negligible vaporizable liquid is present in the inletfluid.

On discharge of particulate polymer product from reactor, it isdesirable and preferable to separate fluid from the product and toreturn the fluid to the recycle line. There are numerous ways known tothe art to accomplish this separation. Product discharge systems whichmay be alternatively employed are, for example, disclosed and claimed inU.S. Pat. No. 4,621,952. Such a system typically employs at least one(parallel) pair of tanks comprising a settling tank and a transfer tankarranged in series and having the separated gas phase returned from thetop of the settling tank to a point in the reactor near the top of thefluidized bed.

In the fluidized bed gas phase reactor embodiment, the reactortemperature of the fluidized bed process herein ranges from 70° C. or75° C., or 80° C. to 90° C. or 95° C. or 100° C. or 110° C. or 115° C. ,wherein a desirable temperature range comprises any upper temperaturelimit combined with any lower temperature limit described herein. Ingeneral, the reactor temperature is operated at the highest temperaturethat is feasible, taking into account the sintering temperature of theinventive polyethylene composition within the reactor and fouling thatmay occur in the reactor or recycle line(s) as well as the impact on theinventive polyethylene composition and catalyst productivity.

The process of the present invention is suitable for the production ofhomopolymers comprising ethylene derived units, or copolymers comprisingethylene derived units and at least one or more other α-olefin(s)derived units.

In order to maintain an adequate catalyst productivity in the presentinvention, it is preferable that the ethylene is present in the reactorat a partial pressure at or greater than 160 psia (1100 kPa), or 190psia (1300 kPa), or 200 psia (1380 kPa), or 210 psia (1450 kPa), or 220psia (1515 kPa), or 230 psia (1585 kPa), or 240 psia (1655 pKa).

The comonomer, e.g. one or more α-olefin comonomers, if present in thepolymerization reactor, is present at any level that will achieve thedesired weight percent incorporation of the comonomer into the finishedpolyethylene. This may be expressed as a mole ratio of comonomer toethylene as described herein, which is the ratio of the gasconcentration of comonomer moles in the cycle gas to the gasconcentration of ethylene moles in the cycle gas. In one embodiment ofthe inventive polyethylene composition production, the comonomer ispresent with ethylene in the cycle gas in a mole ratio range of from 0to 0.1 (comonomer:ethylene); and from 0 to 0.05 in another embodiment;and from 0 to 0.04 in another embodiment; and from 0 to 0.03 in anotherembodiment; and from 0 to 0.02 in another embodiment.

Hydrogen gas may also be added to the polymerization reactor(s) tocontrol the final properties (e.g., I₂₁ and/or I₂) of the inventivepolyethylene composition. In one embodiment, the ratio of hydrogen tototal ethylene monomer (ppm H₂/mol % C₂) in the circulating gas streamis in a range of from 0 to 60:1; in another embodiment, from 0.10:1(0.10) to 50:1 (50); in another embodiment, from 0 to 35:1 (35); inanother embodiment, from 0 to 25:1 (25); in another embodiment, from 7:1(7) to 22:1 (22).

The hafnium based catalyst system, as used herein, refers to a catalystcomposition capable of catalyzing the polymerization of ethylenemonomers and optionally one or more α-olefin co monomers to producepolyethylene. Furthermore, the hafnium based catalyst system comprises ahafnocene component. The hafnocene component may have an averageparticle size in the range of 12 to 35 μm; for example, the hafnocenecomponent may have an average particle size in the range of 20 to 30 μm,e.g. 25μ. The hafnocene component may comprise mono-, bis- ortris-cyclopentadienyl-type complexes of hafnium. In one embodiment, thecyclopentadienyl-type ligand comprises cyclopentadienyl or ligandsisolobal to cyclopentadienyl and substituted versions thereof.Representative examples of ligands isolobal to cyclopentadienyl include,but are not limited to, cyclopentaphenanthreneyl, indenyl, benzindenyl,fluorenyl, octahydrofluorenyl, cyclooctatetraenyl,cyclopentacyclododecene, phenanthrindenyl, 3,4-benzofluorenyl,9-phenylfluorenyl, 8-H-cyclopent[a]acenaphthylenyl, 7H-dibenzofluorenyl,indeno[1,2-9]anthrene, thiophenoindenyl, thiophenofluorenyl,hydrogenated versions thereof (e.g., 4,5,6,7-tetrahydroindenyl, or“H₄Ind”) and substituted versions thereof. In one embodiment, thehafnocene component is an unbridged bis-cyclopentadienyl hafnocene andsubstituted versions thereof. In another embodiment, the hafnocenecomponent excludes unsubstituted bridged and unbridgedbis-cyclopentadienyl hafnocenes, and unsubstituted bridged and unbridgedbis-indenyl hafnocenes. The term “unsubstituted,” as used herein, meansthat there are only hydride groups bound to the rings and no othergroup. Preferably, the hafnocene useful in the present invention can berepresented by the formula (where “Hf” is hafnium):

Cp_(a)HfX_(p)   (1)

wherein n is 1 or 2, p is 1, 2 or 3, each Cp is independently acyclopentadienyl ligand or a ligand isolobal to cyclopentadienyl or asubstituted version thereof bound to the hafnium; and X is selected fromthe group consisting of hydride, halides, C₁ to C₁₀ alkyls and C₂ to C₁₂alkenyls; and wherein when n is 2, each Cp may be bound to one anotherthrough a bridging group A selected from the group consisting of C₁ toC₅ alkylenes, oxygen, alkylamine, silyl-hydrocarbons, andsiloxyl-hydrocarbons. An example of C₁ to C₅ alkylenes include ethylene(—CH₂CH₂—) bridge groups; an example of an alkylamine bridging groupincludes methylamide (—(CH₃)N—); an example of a silyl-hydrocarbonbridging group includes dimethylsilyl (—(CH₃)₂Si—); and an example of asiloxyl-hydrocarbon bridging group includes (—O—(CH₃)₂Si—O—). In oneparticular embodiment, the hafnocene component is represented by formula(1), wherein n is 2 and p is 1 or 2.

As used herein, the term “substituted” means that the referenced grouppossesses at least one moiety in place of one or more hydrogens in anyposition, the moieties selected from such groups as halogen radicalssuch as F, Cl, Br, hydroxyl groups, carbonyl groups, carboxyl groups,amine groups, phosphine groups, alkoxy groups, phenyl groups, naphthylgroups, C₁ to C₁₀ alkyl groups, C₂ to C₁₀ alkenyl groups, andcombinations thereof. Examples of substituted alkyls and aryls includes,but are not limited to, acyl radicals, alkylamino radicals, alkoxyradicals, aryloxy radicals, alkylthio radicals, dialkylamino radicals,alkoxycarbonyl radicals, aryloxycarbonyl radicals, carbamoyl radicals,alkyl- and dialkyl-carbamoyl radicals, acyloxy radicals, acylaminoradicals, arylamino radicals, and combinations thereof. More preferably,the hafnocene component useful in the present invention can berepresented by the formula:

(CpR₅)₂HfX₂   (2)

wherein each Cp is a cyclopentadienyl ligand and each is bound to thehafnium; each R is independently selected from hydrides and C₁ to C₁₀alkyls, most preferably hydrides and C₁ to C₅ alkyls; and X is selectedfrom the group consisting of hydride, halide, C₁ to C₁₀ alkyls and C₂ toC₁₂ alkenyls, and more preferably X is selected from the groupconsisting of halides, C₂ to C₆ alkylenes and C₁ to C₆ alkyls, and mostpreferably X is selected from the group consisting of chloride,fluoride, C₁ to C₅ alkyls and C₂ to C₆ alkylenes. In a most preferredembodiment, the hafnocene is represented by formula (2) above, whereinat least one R group is an alkyl as defined above, preferably a C₁ to C₅alkyl, and the others are hydrides. In a most preferred embodiment, eachCp is independently substituted with from one, two, or three groupsselected from the group consisting of methyl, ethyl, propyl, butyl, andisomers thereof.

In one embodiment, the hafnocene based catalyst system is heterogeneous,i.e. the hafnocene based catalyst may further comprise a supportmaterial. The support material can be any material known in the art forsupporting catalyst compositions; for example, an inorganic oxide; or inthe alternative, silica, alumina, silica-alumina, magnesium chloride,graphite, magnesia, titania, zirconia, and montmorillonite, any of whichcan be chemically/physically modified such as by fluoriding processes,calcining or other processes known in the art. In one embodiment thesupport material is a silica material having an average particle size asdetermined by Malvern analysis of from 1 to 60 mm; or in thealternative, 10 to 40 mm.

In one embodiment, the hafnocene component may be spray-dried hafnocenecomposition containing a micro-particulate filler such as Cabot TS-610.

The hafnocene based catalyst system may further comprise an activator.Any suitable activator known to activate catalyst components for olefinpolymerization may be suitable. In one embodiment, the activator is analumoxane; in the alternative methalumoxane such as described by J. B.P. Soares and A. E. Hamielec in 3(2) POLYMER REACTION ENGINEERING,131-200 (1995). The alumoxane may preferably be co-supported on thesupport material in a molar ratio of aluminum to hafnium (Al:Hf) rangingfrom 80:1 to 200:1, most preferably 90:1 to 140:1.

Such hafnium based catalyst systems are further described in details inthe U.S. Pat. No. 6,242,545 and U.S. Pat. No. 7,078,467, incorporatedherein by reference.

The fibers according to the instant invention comprise the inventivepolyethylene composition, and optionally one or more other polymers. Theinventive fibers may have a denier per filament in the range of lessthan 50 g/9000 m. All individual values and subranges from less than 50g/9000 m are included herein and disclosed herein; for example, thedenier per filament can be from a lower limit of 0.1, 0.5, 1, 5, 10, 15,17, 20, 25, 30, 33, 40, or 44 g/9000 m to an upper limit of 0.5, 1, 5,10, 15, 17, 20, 25, 30, 33, 40, 44, or 50 g/9000 m. For example, theinventive fibers may have a denier per filament in the range of lessthan 40 g/9000 m; or in the alternative, the inventive fibers may have adenier per filament in the range of less than 30 g/9000 m; or in thealternative, the inventive fibers may have a denier per filament in therange of less than 20 g/9000 m; or in the alternative, the inventivefibers may have a denier per filament in the range of less than 10g/9000 m; or in the alternative, the inventive fibers may have a denierper filament in the range of less than 5 g/9000 m; or in thealternative, the inventive fibers may have a denier per filament in therange of less than 3 g/9000 m; or in the alternative, the inventivefibers may have a denier per filament in the range of less than 2 g/9000m; or in the alternative, the inventive fibers may have a denier perfilament in the range of less than 1.5 g/9000 m.

The inventive fibers may have a tenacity in the range of 0.1 to 15g/denier. All individual values and subranges from 0.1 to 15 g/denierare included herein and disclosed herein; for example, the tenacity canbe from a lower limit of 0.1, 0.5, 1, 2, 3, 4, 5, 7, 9, or 10 g/denierto an upper limit of 0.5, 1, 2, 3, 4, 5, 7, 9, 10, 12, or 15 g/denier.For example, the inventive fibers may have a tenacity in the range of0.1 to 10 g/denier; or in the alternative, the inventive fibers may havea tenacity in the range of 0.1 to 7 g/denier; or in the alternative, theinventive fibers may have a tenacity in the range of 0.1 to 5 g/denier;or in the alternative, the inventive fibers may have a tenacity in therange of 0.1 to 4 g/denier; or in the alternative, the inventive fibersmay have a tenacity in the range of 0.1 to 3 g/denier; or in thealternative, the inventive fibers may have a tenacity in the range of0.1 to 2 g/denier; or in the alternative, the inventive fibers may havea tenacity in the range of 0.1 to 1.5 g/denier; or in the alternative,the inventive fibers may have a tenacity in the range of 0.1 to 1.0g/denier; or in the alternative, the inventive fibers may have atenacity in the range of 1.5 to 5 g/denier; or in the alternative, theinventive fibers may have a tenacity in the range of 2 to 5 g/denier; orin the alternative, the inventive fibers may have a tenacity in therange of 2 to 4 g/denier; or in the alternative, the inventive fibersmay have a tenacity in the range of 2.5 to 3.5 g/denier.

The inventive fibers may have an elongation measured in percent of lessthan 1500. All individual values and subranges from less than 1500percent are included herein and disclosed herein; for example, theelongation measured in percent can be from a lower limit of 1, 5, 10,15, 20, 25, 30, 50, 75, 100, 150, 200, 500, or 900 percent to an upperlimit of 5, 10, 15, 20, 25, 30, 50, 75, 100, 150, 200, 300, 500, 900,1000, or 1400 percent. For example, the inventive fibers may have anelongation measured in percent of less than 1400; or in the alternative,the inventive fibers may have an elongation measured in percent of lessthan 1000; or in the alternative, the inventive fibers may have anelongation measured in percent of less than 500; or in the alternative,the inventive fibers may have an elongation measured in percent of lessthan 300; or in the alternative, the inventive fibers may have anelongation measured in percent of less than 200; or in the alternative,the inventive fibers may have an elongation measured in percent of lessthan 150; or in the alternative, the inventive fibers may have anelongation measured in percent of less than 125; or in the alternative,the inventive fibers may have an elongation measured in percent of lessthan 110; or in the alternative, the inventive fibers may have anelongation measured in percent of less than 100; or in the alternative,the inventive fibers may have an elongation measured in percent of lessthan 90; or in the alternative, the inventive fibers may have anelongation measured in percent of less than 80; or in the alternative,the inventive fibers may have an elongation measured in percent of lessthan 70; or in the alternative, the inventive fibers may have anelongation measured in percent of less than 50; or in the alternative,the inventive fibers may have an elongation measured in percent of lessthan 25; or in the alternative, the inventive fibers may have anelongation measured in percent of less than 15.

The inventive fibers may have a boiling water shrink measured in percentafter being annealed at 120° C. in the range of less than 50. Allindividual values and subranges from less than 50 percent are includedherein and disclosed herein; for example, the boiling water shrinkmeasured in percent can be from a lower limit of 0.1, 0.5, 1, 2, 5, 10,15, 20, 25, 30, or 40 percent to an upper limit of 0.5, 1, 2, 5, 10, 15,20, 25, 30, 40, or 45 percent. For example, the inventive fibers mayhave a boiling water shrink measured in percent after being annealed at120° C. in the range of less than 40; or in the alternative, theinventive fibers may have a boiling water shrink measured in percentafter being annealed at 120° C. in the range of less than 30; or in thealternative, the inventive fibers may have a boiling water shrinkmeasured in percent after being annealed at 120° C. in the range of lessthan 35; or in the alternative, the inventive fibers may have a boilingwater shrink measured in percent after being annealed at 120° C. in therange of less than 25; or in the alternative, the inventive fibers mayhave a boiling water shrink measured in percent after being annealed at120° C. in the range of less than 20; or in the alternative, theinventive fibers may have a boiling water shrink measured in percentafter being annealed at 120° C. in the range of less than 15; or in thealternative, the inventive fibers may have a boiling water shrinkmeasured in percent after being annealed at 120° C. in the range of lessthan 10; or in the alternative, the inventive fibers may have a boilingwater shrink measured in percent after being annealed at 120° C. in therange of less than 5; or in the alternative, the inventive fibers mayhave a boiling water shrink measured in percent after being annealed at120° C. in the range of less than 4; or in the alternative, theinventive fibers may have a boiling water shrink measured in percentafter being annealed at 120° C. in the range of less than 2; or in thealternative, the inventive fibers may have a boiling water shrinkmeasured in percent after being annealed at 120° C. in the range of lessthan 1. In one embodiment, the inventive fibers are drawn and annealedat a constant length at equal to or less than 120° C.

Inventive fibers according to the instant invention may be produced viadifferent techniques. The inventive fibers may, for example, be producedvia melt spinning. The inventive fibers according to instant inventionmay be continuous filaments, or in the alternative, the inventive fibersmay be staple fibers. Continuous filaments may further be optionallycrimped, and then cut to produce staple fibers. The inventive fibersinclude, but are not limited to, mono-component fibers, bi-componentfibers, and/or multi-component fibers. Exemplary bi-component fibersinclude, but are not limited to, sheath/core, islands in the sea,segmented pie, and combination thereof. The inventive fibers may includethe inventive polyethylene composition according to the instantinvention as an outer layer, e.g. sheath, alone or in combination withone or more polymers. The inventive fibers may include the inventivepolyethylene composition according to the instant invention as an innerlayer, e.g. core, alone or in combination with one or more polymers. Theinventive fibers or the inventive fiber components, i.e. inner layer andouter layer, according to the instant invention may be mono-constituent,i.e. only inventive polyethylene composition; or in the alternative, theinventive fibers or the inventive fiber components, i.e. inner layer andouter layer according to the instant invention may be multi-constituent,i.e. a blend of inventive polyethylene composition and one or morepolymers. The term outer layer, as used herein, refers to at least anyportion of the fiber surface. The term inner layer, as used herein,refers to any portion below the fiber surface.

In melt spinning, the inventive polyethylene composition is meltextruded and forced through the fine orifices in a metallic plate calledspinneret into air or other gas, where it is cooled and solidified. Thesolidified filaments may be drawn-off via rotating rolls, or godets, andwound onto bobbins.

Inventive fabrics according to instant invention include, but are notlimited to, non-woven fabrics, woven fabrics, and combination thereof.

The non-woven fabrics according to the instant invention may befabricated via different techniques. Such methods include, but are notlimited to, melt blown process, spunbond process, carded web process,air laid process, thermo-calendering process, adhesive bonding process,hot air bonding process, needle punch process, hydroentangling process,electrospinning process, and combinations thereof.

In melt blown process, the inventive non-woven fabric is formed byextruding molten polyethylene composition of the instant inventionthrough a die, then, attenuating and/or optionally breaking theresulting filaments with hot, high-velocity air or stream therebyforming short or long fiber lengths collected on a moving screen wherethey bond during cooling.

In the alternative, the melt blown process generally includes thefollowing steps: (a) Extruding strands from a spinneret; (b)Simultaneously quenching and attenuating the polymer stream immediatelybelow the spinneret using streams of high velocity heated air; (c)Collecting the drawn strands into a web on a foraminous surface.Meltblown webs can be bonded by a variety of means including, but notlimited to, autogeneous bonding, i.e. self bonding without furthertreatment, thermo-calendering process, adhesive bonding process, hot airbonding process, needle punch process, hydroentangling process, andcombinations thereof.

In spunbond process, the fabrication of non-woven fabric includes thefollowing steps: (a) extruding strands of the inventive polyethylenecomposition from a spinneret; (b) quenching the strands of the inventivepolyethylene composition with a flow of air which is generally cooled inorder to hasten the solidification of the molten strands of theinventive polyethylene composition; (c) attenuating the filaments byadvancing them through the quench zone with a draw tension that can beapplied by either pneumatically entraining the filaments in an airstream or by wrapping them around mechanical draw rolls of the typecommonly used in the textile fibers industry; (d) collecting the drawnstrands into a web on a foraminous surface, e.g. moving screen or porousbelt; and (e) bonding the web of loose strands into the non-wovenfabric. Bonding can be achieved by a variety of means including, but notlimited to, thermo-calendering process, adhesive bonding process, hotair bonding process, needle punch process, hydroentangling process, andcombinations thereof.

The inventive woven fabrics according to the instant invention may befabricated from the inventive fibers via different techniques. Suchmethods include, but are not limited to, weaving process, and knittingprocess.

In the weaving process, two sets of yarns, i.e. warp and weft, areinterlaced to form the inventive woven fabric. The manner in which thetwo sets of yarns are interlaced determines the weave. The weavingprocess may be achieved via different equipments including, but notlimited to, Dobby loom, Jacquard loom, and Power loom. By using variouscombinations of the three basic weaves, i.e. plain, twill, and satin, itis possible to produce an almost unlimited variety of constructions.

In the knitting process, the inventive woven fabric is formed byinterlocking a series of loops of one or more yarns. The two majorclasses of knitting include, but are not limited to, wrap knitting andweft knitting.

Warp Knitting is a type of knitting in which the yarns generally runlengthwise in the fabric. The yarns are prepared as warps on beams withone or more yarns for each needle. Weft Knitting is, however, a commontype of knitting, in which one continuous thread runs crosswise in thefabric making all of the loops in one course. Weft knitting types arecircular and flat knitting.

The inventive fabrics according to the instant invention possessimproved softness and drapeability properties. The inventive fabricsaccording to the instant invention further provide higher tenacityfabrics. The inventive polyethylene composition further providesimproved processability and spinnability at lower melt indices, forexample, in the range of less than 10 g/10 minutes, or in thealternative, in the range of less than 5 g/10 minutes. The low levels ofvinyl unsaturations in the inventive polyethylene composition are alsoimportant because such low levels of the vinyl unsaturations provide theinstant inventive polyethylene composition with improved processability.

The inventive fabrics according to the instant invention may have anabrasion resistance in the range of less than or equal to 5 percent byweight of abraded fibers per weight of the fabric prior to abrasiontesting. All individual values and subranges from less than or equal to5 weight percent are included herein and disclosed herein; for example,abrasion resistance can be from a lower limit of 0.1, 0.5, 1, 2, 3,or3.5 weight percent to an upper limit of 0.5, 1, 2, 3, 3.5, 4, or 5weight percent. For example, the inventive fabrics may have an abrasionresistance in the range of less than or equal to 4 percent by weight ofabraded fibers per weight of the fabric prior to abrasion testing; or inthe alternative, the inventive fabrics may have an abrasion resistancein the range of less than or equal to 3.5 percent by weight of abradedfibers per weight of the fabric prior to abrasion testing; or in thealternative, the inventive fabrics may have an abrasion resistance inthe range of less than or equal to 3 percent by weight of abraded fibersper weight of the fabric prior to abrasion testing; or in thealternative, the inventive fabrics may have an abrasion resistance inthe range of less than or equal to 2.5 percent by weight of abradedfibers per weight of the fabric prior to abrasion testing; or in thealternative, the inventive fabrics may have an abrasion resistance inthe range of less than or equal to 2 percent by weight of abraded fibersper weight of the fabric prior to abrasion testing.

The inventive fabrics comprising one or more fibers having a denier perfilament in the range of less than 5 g/9000 m, e.g. 2 g/9000 m, may havea smoothness value in the range of less than 2. All individual valuesand subranges from less than 2 are included herein and disclosed herein;for example, the inventive fabrics comprising one or more fibers havinga denier per filament in the range of less than 5 g/9000 m, e.g. 2g/9000 m, may have a smoothness value in the range of less than 1.8; orin the alternative, the inventive fabrics comprising one or more fibershaving a denier per filament in the range of less than 5 g/9000 m, e.g.2 g/9000 m, may have a smoothness value in the range of less than 1.7;or in the alternative, the inventive fabrics comprising one or morefibers having a denier per filament in the range of less than 5 g/9000m, e.g. 2 g/9000 m, may have a smoothness value in the range of lessthan 1.5; or in the alternative, the inventive fabrics comprising one ormore fibers having a denier per filament in the range of less than 5g/9000 m, e.g. 2 g/9000 m, may have a smoothness value in the range ofless than 1.3.

The inventive fabrics comprising one or more fibers having a denier perfilament in the range of less than 5 g/9000 m, e.g. 2 g/9000 m, may havea wax value in the range of greater than 7. All individual values andsubranges from greater than 7 are included herein and disclosed herein;for example, the inventive fabrics comprising one or more fibers havinga denier per filament in the range of less than 5 g/9000 m, e.g. 2g/9000 m, may have a wax value in the range of greater than 7.5.

The inventive fabrics comprising one or more fibers having a denier perfilament in the range of less than 5 g/9000 m, e.g. 2 g/9000 m, may havea hand friction value in the range of less than 3.5. All individualvalues and subranges from less than 3.5 are included herein anddisclosed herein; for example, the inventive fabrics comprising one ormore fibers having a denier per filament in the range of less than 5g/9000 m, e.g. 2 g/9000 m, may have a hand friction value in the rangeof less than 3.3; or in the alternative, the inventive fabricscomprising one or more fibers having a denier per filament in the rangeof less than 5 g/9000 m, e.g. 2 g/9000 m, may have a hand friction valuein the range of less than 3.0; or in the alternative, the inventivefabrics comprising one or more fibers having a denier per filament inthe range of less than 5 g/9000 m, e.g. 2 g/9000 m, may have a handfriction value in the range of less than 2.5; or in the alternative, theinventive fabrics comprising one or more fibers having a denier perfilament in the range of less than 5 g/9000 m, e.g. 2 g/9000 m, may havea hand friction value in the range of less than 2.0.

The inventive fabrics comprising one or more fibers having a denier perfilament in the range of less than 5 g/9000 m, e.g. 2 g/9000 m, may havea stiffness value in the range of less than 1.1. All individual valuesand subranges from less than 1.1 are included herein and disclosedherein; for example, the inventive fabrics comprising one or more fibershaving a denier per filament in the range of less than 5 g/9000 m, e.g.2 g/9000 m, may have a stiffness value in the range of less than 1.0; orin the alternative, the inventive fabrics comprising one or more fibershaving a denier per filament in the range of less than 5 g/9000 m, e.g.2 g/9000 m, may have a stiffness value in the range of less than 0.8; orin the alternative, the inventive fabrics comprising one or more fibershaving a denier per filament in the range of less than 5 g/9000 m, e.g.2 g/9000 m, may have a stiffness value in the range of less than 0.7.

The inventive fabrics comprising one or more fibers having a denier perfilament in the range of less than 5 g/9000 m, e.g. 2 g/9000 m, may havea smoothness value in the range of less than 2, a wax value in the rangeof greater than 7, a hand friction value in the range of less than 3.5,and a stiffness value in the range of less than 1.1.

The inventive fabrics comprising one or more fibers having a denier perfilament in the range of 5 to 7 g/9000 m, e.g. 6 g/9000 m, may have asmoothness value in the range of less than 8. All individual values andsubranges from less than 8 are included herein and disclosed herein; forexample, the inventive fabrics comprising one or more fibers having adenier per filament in the range of 5 to 7 g/9000 m, e.g. 6 g/9000 m,may have a smoothness value in the range of less than 7; or in thealternative, the inventive fabrics comprising one or more fibers havinga denier per filament in the range of 5 to 7 g/9000 m, e.g. 6 g/9000 m,may have a smoothness value in the range of less than 6.

The inventive fabrics comprising one or more fibers having a denier perfilament in the range of 5 to 7 g/9000 m, e.g. 6 g/9000 m, may have awax value in the range of greater than 8. All individual values andsubranges from greater than 8 are included herein and disclosed herein;for example, the inventive fabrics comprising one or more fibers havinga denier per filament in the range of 5 to 7 g/9000 m, e.g. 6 g/9000 m,may have a wax value in the range of greater than 8.5.

The inventive fabrics comprising one or more fibers having a denier perfilament in the range of 5 to 7 g/9000 m, e.g. 6 g/9000 m, may have ahand friction value in the range of less than 7.0. All individual valuesand subranges from less than 7.0 are included herein and disclosedherein; for example, the inventive fabrics comprising one or more fibershaving a denier per filament in the range of 5 to 7 g/9000 m, e.g. 6g/9000 m, may have a hand friction value in the range of less than 6.0.

The inventive fabrics comprising one or more fibers having a denier perfilament in the range of 5 to 7 g/9000 m, e.g. 6 g/9000 m, may have astiffness value in the range of less than 3.0. All individual values andsubranges from less than 3.0 are included herein and disclosed herein;for example, the inventive fabrics comprising one or more fibers havinga denier per filament in the range of 5 to 7 g/9000 m, e.g. 6 g/9000 m,may have a stiffness value in the range of less than 2.0; or in thealternative, the inventive fabrics comprising one or more fibers havinga denier per filament in the range of 5 to 7 g/9000 m, e.g. 6 g/9000 m,may have a stiffness value in the range of less than 1.8.

The inventive fabrics comprising one or more fibers having a denier perfilament in the range of 5 to 7 g/9000 m, e.g. 6 g/9000 m, may have asmoothness value in the range of less than 8, a wax value in the rangeof greater than 8, a hand friction value in the range of less than 7,and a stiffness value in the range of less than 3.

The inventive fabrics possess improved resistance to dryer.Additionally, the inventive fabrics are substantially waterproof.

The inventive polyethylene composition may be used in a variety ofend-use applications including, but not limited to, carpet, apparel,upholstery, non-woven fabrics, woven fabrics, artificial turf, medicalgowns, hospital wraps, and the like.

EXAMPLES

The following examples illustrate the present invention but are notintended to limit the scope of the invention. The examples of theinstant invention demonstrate that the inventive fabrics according tothe instant invention possess improved softness and drapeabilityproperties, and higher tenacity. These examples further demonstrate thatthe inventive polyethylene composition provides improved processabilityand spinnability at lower melt indices, for example, in the range ofless than 10 g/10 minutes, or in the alternative, in the range of lessthan 5 g/10 minutes.

Inventive Polyethylene Samples 1-3 Catalyst Component Preparation

The hafnocene component can be prepared by techniques known in the art.For example, HfCl₄ (1.00 equiv.) can be added to ether at −30 to −50° C.and stirred to give a white suspension. The suspension can then bere-cooled to −30 to −50° C., and then lithium propylcyclopentadienide(2.00 equiv.) added in portions. The reaction will turn light brown andbecome thick with suspended solid on adding the lithiumpropylcyclopentadienide. The reaction can then be allowed to warm slowlyto room temperature and stirred for 10 to 20 hours. The resultant brownmixture can then be filtered to give brown solid and a straw yellowsolution. The solid can then be washed with ether as is known in theart, and the combined ether solutions concentrated to under vacuum togive a cold, white suspension. Off-white solid product is then isolatedby filtration and dried under vacuum, with yields of from 70 to 95percent.

Catalyst Composition Preparation

The catalyst compositions should be made at a Al/Hf mole ratio of fromabout 80:1 to 130:1 and the hafnium loading on the finished catalystshould be from about 0.6 to 0.8 weight percent Hf using the followinggeneral procedure. Methylaluminoxane (MAO) in toluene should be added toa clean, dry vessel and stirred at from 50 to 80 rpm and at atemperature in the range of 60 to 100° F. Additional toluene can then beadded while stiffing. The hafnocene can then be dissolved in toluene andplaced in the vessel with the MAO. The metallocene/MAO mixture can thenbe stirred at for from 30 min to 2 hours. Next, an appropriate amount ofsilica (average particle size in the range of 22 to 28 μm, dehydrated at600° C.) can be added and stirred for another hour or more. The liquidcan then be decanted and the catalyst composition dried at elevatedtemperature under flowing nitrogen while being stirred.

Polymerization Process

The ethylene/1-hexene copolymers were produced in accordance with thefollowing general procedure. The catalyst composition comprised a silicasupported bis(n-propylcyclopentadienyl) hafnium dichloride withmethalumoxane, the Al:Hf ratio being from about 80:1 to 130:1. Thecatalyst composition was injected dry into a fluidized bed gas phasepolymerization reactor. More particularly, polymerization was conductedin a 336.5-419.3 mm ID diameter gas-phase fluidized bed reactoroperating at approximately 2068 to 2586 kPa total pressure. The reactorbed weight was approximately 41-91 kg. Fluidizing gas was passed throughthe bed at a velocity of approximately 0.49 to 0.762 m per second. Thefluidizing gas exiting the bed entered a resin disengaging zone locatedat the upper portion of the reactor. The fluidizing gas then entered arecycle loop and passed through a cycle gas compressor and water-cooledheat exchanger. The shell side water temperature was adjusted tomaintain the reaction temperature to the specified value. Ethylene,hydrogen, 1-hexene and nitrogen were fed to the cycle gas loop justupstream of the compressor at quantities sufficient to maintain thedesired gas concentrations. Gas concentrations were measured by anon-line vapor fraction analyzer. Product (the inventive polyethyleneparticles) was withdrawn from the reactor in batch mode into a purgingvessel before it was transferred into a product bin. Residual catalystand activator in the resin was deactivated in the product drum with awet nitrogen purge. The catalyst was fed to the reactor bed through astainless steel injection tube at a rate sufficient to maintain thedesired polymer production rate. There were 3 separate polymerizationruns conducted using this general process, each with varying conditionsas elucidated in the Table I. Table II summarizes the properties of theinventive polyethylene samples 1-3 that resulted from each run.

Inventive Fibers 1-3

Inventive polyethylene samples 1-3 were formed into inventive fibers1-3, respectively, according to the process described below, and testedfor their physical properties. The results are shown in Table III.

Inventive fibers 1-3 were spun at a 230° C. melt temperature through a48-hole spinneret (0.5 mm×4 L/D capillaries). The speed of the winderwas at 1500 m/min, and the godet speeds were varied up and down to varythe draw ratio. Relaxation between Godet C and the Winder was less than5%. The draw ration between Godet A and Godet B was 3.25, 4.8, and 2.2for inventive fiber 1, 2, and 3, respectively. Quench air was at 12° C.and it was fed from one side only; quench cabinet length was two meters.The three godets were set at 60° C., 100° C., and 110° C., respectively.Packages of yarn were collected for mechanical testing, which wasconducted according to the following procedure. Inventive fibers 1-3were set in conventional fiber horn jaws at an initial length of 8inches. Top jaw speed was set to 8 inches/minute. Five replicates wererun. Maximum force and elongation at maximum forces were recorded andaveraged, and the results are shown in Table III.

The inventive fiber 1-3 were tested for their boiling water shrinkageaccording to the following procedure. Inventive fiber 1-3 were cut fromthe yarn package, marked for length, submerged for 15 seconds in hotwater, then withdrawn and remeasured. The boiling water shrinkageresults for the unannealed inventive fibers 1-3 are shown in Table IV.The inventive fibers 1-3 were heat-set at constant length in a hot airoven for 7 minutes at 120° C. prior to retesting in boiling water. Theboiling water shrinkage results for the annealed inventive fibers 1-3are also shown in Table IV.

Inventive Fibers 4 and 5

Inventive polyethylene sample 2 was formed into inventive fibers 4 and 5according to the process described below, and tested for its physicalproperties. The results are shown in Table III.

Inventive fibers 4 and 5 were spun at a 230° C. melt temperature througha 48-hole spinneret (0.5 mm×4 L/D capillaries) and 144-hole spinneret,respectively. The speed of the winder was at 1500 m/min, and the godetspeeds were varied up and down to vary the draw ratio. Relaxationbetween Godet C and the Winder was less than 5%. The draw ration betweenGodet A and Godet B was 3.8 and 2 for inventive fibers 4 and 5respectively. Quench air was at 12° C. and it was fed from one sideonly; quench cabinet length was two meters. The three godets were set at60° C., 100° C., and 110° C., respectively.

Inventive Knitted Fabrics A and B

Inventive fibers 4 and 5 were knitted to form inventive knitted fabricsA and B under the following Knitting Conditions. The inventive fibers 4and 5 were knitted on an FAK (Fabric Analysis Knitter) knitter typicallyused to check quality on lots of yarn lots. The inventive knittedfabrics A and B were approximately 500 g/m² basis weight in a “plainjersey knit.” The inventive knitted fabrics A and B were each a fabricwith 28 rows (or “courses”) per inch.

Inventive knitted fabrics A and B were tested for their perception ofsoftness based on the smoothness, waxy, stiffness, and hand frictionaccording to the Handfeel Test, as described hereinbelow. The results,i.e. the average ratings, are shown in Tables V-IX.

Inventive knitted fabrics A and B were also tested for abrasionresistance according to the following procedure. The abrasion resistancewas determined using a Sutherland 2000 Rub Tester. Samples at adimension of 11.0 cm×4.0 cm (4.33″×1.57″) were cut and mounted to thebase using double stick tape. 320-Grit sandpaper was then mounted to a2-lb weight, and the weight placed on the sample. An arm then moved theweight back and forth in a continuous motion at Speed 2. One cycle isone movement back and forth of the weight against the fabric. Sixtycycles were required before the samples displayed any visible fuzzing.When adhesive tape was applied to the surface of the inventive kittedfabrics A and B, and comparative knitted fabrics A-C, and then rippedoff, very few fibers were collected on the tape from either theinventive kitted fabrics A or B or comparative knitted fabrics A-C;thus, it was indicating that the inventive kitted fabrics A and B havemaintained their integrity at least at the same level as the comparativeknitted fabrics A-C. The samples were tested twice, and their averageresults are shown in Table X.

Comparative Polymer Compositions 1-3

Comparative polymer composition 1 is a polypropylene homopolymer havinga melt flow rate of 9.5 (230° C. and 2.16 kg load), which iscommercially available from The Dow Chemical Company. The properties ofcomparative polymer composition 1 are shown in Table IIA.

Comparative polymer composition 2 is a polypropylene homopolymer havinga melt flow rate of 38 (230° C. and 2.16 kg load), which is commerciallyavailable from The Dow Chemical Company. The properties of comparativepolymer composition 2 are shown in Table IIA.

Comparative polymer composition 3 is a linear low density polyethylene(ethylene/octene copolymer) having a density of approximately 0.941g/cm³, and a melt index (I₂) of approximately 4, which is commerciallyavailable from The Dow Chemical Company. The properties of comparativepolymer composition 3 are shown in Table IIA.

Comparative Fibers 1-2

Comparative polymer composition 1 and 2 were formed into comparativefibers 1 and 2, respectively, according to the process described below,and tested for their physical properties. The results are shown in TableIIIA.

Comparative fibers 1-2 were spun at a 230° C. melt temperature through a48-hole spinneret (0.5 mm×4 L/D capillaries). The speed of the winderwas at 1500 m/min, and the godet speeds were varied up and down to varythe draw ratio. Relaxation between Godet C and the Winder was less than5%. The draw ration between Godet A and Godet B (V₂:V₁) was 2.75, and3.6 for comparative fibers 1, and 2, respectively. Quench air was at 12°C. and it was fed from one side only; quench cabinet length was twometers. The three godets were set at 60° C., 100° C., and 110° C.,respectively. Packages of yarn were collected for mechanical testing,which was conducted according to the following procedure. Comparativefibers 1-2 were set in conventional fiber horn jaws at an initial lengthof 8 inches. Top jaw speed was set to 8 inches/minute. Five replicateswere run. Maximum force and elongation at maximum forces were recordedand averaged, and the results are shown in Table IIIA.

The comparative fiber 2 was tested for its boiling water shrinkageaccording to the following procedure. Comparative fiber 2 was cut fromthe yarn package, marked for length, submerged for 15 seconds in hotwater, then withdrawn and remeasured. The boiling water shrinkageresults for the unannealed comparative fiber 2 are shown in Table IV.The comparative fiber 2 was heat-set at constant length in a hot airoven for 7 minutes at 120° C. prior to retesting in boiling water. Theboiling water shrinkage results for the annealed comparative fiber 2 arealso shown in Table IV.

Comparative Fibers 1A-3A

Comparative polymer composition 1-3 were also formed into comparativefibers 1A-3A, respectively.

Comparative fibers 1A-3A were spun at a 230° C. melt temperature througha 48-hole spinneret (0.5 mm×4 L/D capillaries). The speed of the winderwas at 1500 m/min, and the godet speeds were varied up and down to varythe draw ratio. Relaxation between Godet C and the Winder was less than5%. The draw ration between Godet A and Godet B (V₂:V₁) was 2.8, 2, and2.2 for comparative fibers 1A, 2A, and 3A, respectively. Quench air wasat 12° C., and it was fed from one side only; quench cabinet length wastwo meters. The three godets were set at 60° C., 100° C., and 110° C.,respectively. Fiber properties and maximum draw ratios are shown inTable IIIA.

Comparative Knitted Fabrics A-C

Comparative fibers 1A-3A were knitted to form comparative knittedfabrics A-C under the following Knitting Conditions. The comparativefibers 1A-3A were knitted on an FAK (Fabric Analysis Knitter) knittertypically used to check quality on lots of yarn lots. The comparativeknitted fabrics A-C were approximately 500 g/m² basis weight in a “plainjersey knit.” Each comparative knitted fabric A-C was a fabric with 28rows (or “courses”) per inch.

Comparative knitted fabrics A-C were tested for their perception ofsoftness based on the smoothness, waxy, stiffness, and hand frictionaccording to the Handfeel Test, as described hereinbelow. The results,i.e. the average ratings, are shown in Tables V-IX.

Comparative knitted fabrics A-C were tested for abrasion resistanceaccording to the following procedure. The abrasion resistance wasdetermined using a Sutherland 2000 Rub Tester. Samples at a dimension of11.0 cm×4.0 cm (4.33″×1.57″) were cut and mounted to the base usingdouble stick tape. 320-Grit sandpaper was then mounted to a 2-lb weight,and the weight placed on the sample. An arm then moved the weight backand forth in a continuous motion at Speed 2. One cycle is one movementback and forth of the weight against the fabric. Sixty cycles wererequired before the samples displayed any visible fuzzing. When adhesivetape was applied to the surface of the inventive kitted fabrics A and B,and comparative knitted fabrics A-C, and then ripped off, very fewfibers were collected on the tape from either the inventive kittedfabrics A or B or comparative knitted fabrics A-C. The samples weretested twice, and their average results are shown in Table X.

TABLE I Measurement Units Inventive 2 Inventive 3 Reactor Temperature °C. 95.0 85.0 Isopentane % mole percent 4.8 5.1 Ethylene Partial Pressurepsia 225.0 225.0 C6/C2 molar ratio unitless 0.0016 0.0015 Hydrogen Vaporppm 320 345 Concentration Continuity Additive amount ppm(w) 6 6 in resinHf amount in resin ppm(w) 0.87 0.82 Al amount in resin ppm(w) 11.3 13.2

TABLE II Measurement Units Inventive PE 1 Inventive PE 2 Inventive PE 3Density g/cm³ 0.9417 0.954 0.9557 I₂ g/10 min 5.89 10.4 18.9 I₅ g/10 min14.78 27.2 47.27 I₁₀ g/10 min 34.97 65.8 116.2 I₂₁ g/10 min 101.5 201.3371.1 I_(10/)I₂ — 5.93 6.3 6.1 I₂₁/I₂ — 17.2 19.3 19.6 Conventional GPCMn g/mol 27560 19600 18710 Mw g/mol 68350 62670 49680 Mz g/mol 140400127700 107800 Mw/Mn unitless 2.48 3.20 2.66 Mz/Mw unitless 2.05 2.042.05 Absolute GPC Mn absolute g/mol 47763 18204 18452 Mw absolute g/mol115430 62770 52290 Mz(BB) g/mol 130400 131000 108100 Mz(BB)/Mw(avg)unitless 1.89 2.22 2.21 Shear Viscosity at ~3000 s⁻¹ Pa-s 132.4 119.2methyls per 1000 C's 2.04 0.87 1.02 trans per 1000 C's 0.067 0.033 0.074vinyls per 1000 C's 0.023 0.002 0.000

TABLE IIA Comparative Comparative Comparative Polymer Polymer PolymerMeasurement Units Composition 1 Composition 2 Composition 3 Densityg/cm³ 0.9 0.9 0.941 I₂ g/10 min — — 4 I_(10/)I₂ — — — 6.8 Melt Flow Rate(I₂ @ 230° C.) g/10 min 9.5 38 — Conventional GPC Mn g/mol 55,000 54,00024,000 Mw g/mol 245,000 160,000 83,000 Mz g/mol 670,000 340,000 230,000Mw/Mn unitless 4.5 3.0 3.5 Mz/Mw unitless 2.7 2.1 2.8

TABLE III Inventive Inventive Inventive Inventive Inventive MeasurementUnits Fiber 1 Fiber 2 Fiber 3 Fiber 4 Fiber 5 Yarn Denier g/9000 m 146147 146 300 299 Denier per Filament (dpf) g/9000 m 3.0 3.1 3.0 6 2Tenacity g/denier 2.6 2.75 0.94 — — Elongation % 61 94 175 — — Young'sModulus g/denier — — — — — Maximum Draw Ratio V₂/V₁ 3.25 4.8 2.2 3.8 2

TABLE IIIA Comparative Comparative Comparative Comparative ComparativeMeasurement Units Fiber 1 Fiber 2 Fiber 1A Fiber 2A Fiber 3A Yarn Denierg/9000 m 150 150 309 309 302 Denier per Filament (dpf) g/9000 m 3.1 3.16 2.0 6 Tenacity g/denier 4.3 4.2 — — — Elongation % 51 23 — — — Young'sModulus g/denier — — — — — Maximum Draw Ratio V₂/V₁ 2.75 3.6 2.8 2 2.2

TABLE IV Comparative Inventive Inventive Inventive Measurement UnitsFiber 2 Fiber 1 Fiber 2 Fiber 3 Boiling Water Shrinkage % of initial 7.426 15 17 (Unannealed) length Boiling Water Shrinkage % of initial 1.73.3 1.8 2.8 (annealed at constant length length in hot air at 120° C.)Tenacity (annealed at constant g/denier 5.1 2.6 2.9 0.8 length in hotair at 120° C.) Elongation (annealed at % 20 55 61 113 constant lengthin hot air at 120° C.)

TABLE V Smoothness Attribute Scale Rating Mean Sample 0 1 1.30 Inv. FabB 1.99 Standard 2 3 3.71 Comp Fab C 4 4.26 Comp Fab B 5 5.30 Inv Fab A 67 8 8.35 Comp Fab A 9 10 11 12 13 14 15

TABLE VI Waxy Attribute Scale Rating Mean Sample 0 1 2 3 4 5 6 7 7.51Inv Fab B 7.75 Com Fab B 8 8.07 Comp Fab C 8.21 Inv Fab A 9 9.23 CompFab A 10 11 12 12.94 Standard 13 14 15

TABLE VII Hand Friction Attribute Scale Rating Mean Sample 0 1 1.85 InvFab B 2 3 3.59 Com Fab C 4 5 5.48 Comp Fab B 5.90 Inv Fab A 6 7 7.58Comp Fab A 8 8.00 Standard 9 10 11 12 13 14 15

TABLE VIII Stiffness Attribute Scale Rating Mean Sample 0 0.52 Inv Fab B1 1.18 and 1.25 Comp Fabs C & B 1.58 and 1.84 Inv Fab A & Standard 2 33.82 Comp fab A 4 5 6 7 8 9 10 11 12 13 14 15

TABLE IX Smoothness, Waxy, Hand Friction, and Stiffness Attributes TOTALWaxy Hand Friction Stiffness (Avg. of Smooth Rating 15-Waxy RatingRating C.1, 3, 4, Samples Evaluated Rating (C.1) (C.2) (C.3) (C.4) (C.5)and 5) Inv Fab B 1.30 7.51 7.49 1.85 0.52 11.2 Comp Fab B 4.26 7.75 7.255.48 1.25 18.2 Inv Fab A 5.30 8.21 6.79 5.90 1.58 19.6 Comp Fab A 8.259.23 5.77 7.58 3.82 25.4 Comp Fab C 3.71 8.07 6.93 3.59 1.18 15.4 Cotton(Std)) 1.99 12.94 2.06 8.00 1.84 13.9

TABLE X Average Abrasion Sample (Percent Loss in Weight) InventiveFabric A 0.7 Inventive Fabric B 0.8 Comparative Fabric A 0.8 ComparativeFabric B 0.8 Comparative Fabric C 0.6

Test Methods Test methods include the following:

Density (g/cm³) was measured according to ASTM-D 792-03, Method B, inisopropanol. Specimens were measured within 1 hour of molding afterconditioning in the isopropanol bath at 23° C. for 8 min to achievethermal equilibrium prior to measurement. The specimens were compressionmolded according to ASTM D-4703-00 Annex A with a 5 min initial heatingperiod at about 190° C. and a 15° C./min cooling rate per Procedure C.The specimen was cooled to 45° C. in the press with continued coolinguntil “cool to the touch.”

Melt index (I₂) was measured at 190° C. under a load of 2.16 kgaccording to ASTM D-1238-03.

Melt flow rate (I₅) was measured at 190° C. under a load of 5.0 kgaccording to ASTM D-1238-03.

Melt flow rate (I₁₀) was measured at 190° C. under a load of 10.0 kgaccording to ASTM D-1238-03.

Melt flow rate (I₂₁) was measured at 190° C. under a load of 21.6 kgaccording to ASTM D-1238-03.

Weight average molecular weight (M_(w)) and number average molecularweight (M_(n)) were determined according to methods known in the artusing triple detector GPC, as described herein below.

The molecular weight distributions of the ethylene polymers weredetermined by gel permeation chromatography (GPC). The chromatographicsystem consisted of a Waters (Millford, Mass.) 150° C. high temperaturegel permeation chromatograph, equipped with a Precision Detectors(Amherst, Mass.) 2-angle laser light scattering detector Model 2040. The15° angle of the light scattering detector was used for calculationpurposes. Data collection was performed using Viscotek TriSEC softwareversion 3 and a 4-channel Viscotek Data Manager DM400. The system wasequipped with an on-line solvent degas device from Polymer Laboratories.The carousel compartment was operated at 140° C. and the columncompartment was operated at 150° C. The columns used were four Shodex HT806M 300 mm, 13 μm columns and one Shodex HT803M 150 mm, 12 μm column.The solvent used was 1,2,4 trichlorobenzene. The samples were preparedat a concentration of 0.1 grams of polymer in 50 milliliters of solvent.The chromatographic solvent and the sample preparation solvent contained200 μg/g of butylated hydroxytoluene (BHT). Both solvent sources werenitrogen sparged. Polyethylene samples were stirred gently at 160° C.for 4 hours. The injection volume used was 200 microliters, and the flowrate was 0.67 milliliters/min. Calibration of the GPC column set wasperformed with 21 narrow molecular weight distribution polystyrenestandards, with molecular weights ranging from 580 to 8,400,000 g/mol,which were arranged in 6 “cocktail” mixtures with at least a decade ofseparation between individual molecular weights. The standards werepurchased from Polymer Laboratories (Shropshire, UK). The polystyrenestandards were prepared at 0.025 grams in 50 milliliters of solvent formolecular weights equal to, or greater than, 1,000,000 g/mol, and 0.05grams in 50 milliliters of solvent for molecular weights less than1,000,000 g/mol. The polystyrene standards were dissolved at 80° C. withgentle agitation for 30 minutes. The narrow standards mixtures were runfirst, and in order of decreasing highest molecular weight component, tominimize degradation. The polystyrene standard peak molecular weightswere converted to polyethylene molecular weights using the followingequation (as described in Williams and Ward, J. Polym. Sci., Polym.Let., 6, 621 (1968)):

Mpolyethylene=A×(Mpolystyrene)^(B),

where M is the molecular weight, A has a value of 0.41 and B is equal to1.0. The Systematic Approach for the determination of multi-detectoroffsets was done in a manner consistent with that published by Balke,Mourey, et al. (Mourey and Balke, Chromatography Polym. Chpt 12, (1992)and Balke, Thitiratsakul, Lew, Cheung, Mourey, Chromatography Polym.Chpt 13, (1992)), optimizing dual detector log results from Dow broadpolystyrene 1683 to the narrow standard column calibration results fromthe narrow standards calibration curve using in-house software. Themolecular weight data for off-set determination was obtained in a mannerconsistent with that published by Zimm (Zimm, B. H., J. Chem. Phys., 16,1099 (1948)) and Kratochvil (Kratochvil, P., Classical Light Scatteringfrom Polymer Solutions, Elsevier, Oxford, N.Y. (1987)). The overallinjected concentration used for the determination of the molecularweight was obtained from the sample refractive index area and therefractive index detector calibration from a linear polyethylenehomopolymer of 115,000 g/mol molecular weight, which was measured inreference to NIST polyethylene homopolymer standard 1475. Thechromatographic concentrations were assumed low enough to eliminateaddressing 2^(nd) Virial coefficient effects (concentration effects onmolecular weight). Molecular weight calculations were performed usingin-house software. The calculation of the number-average molecularweight, weight-average molecular weight, and z-average molecular weightwere made according to the following equations, assuming that therefractometer signal is directly proportional to weight fraction. Thebaseline-subtracted refractometer signal can be directly substituted forweight fraction in the equations below. Note that the molecular weightcan be from the conventional calibration curve or the absolute molecularweight from the light scattering to refractometer ratio. An improvedestimation of z-average molecular weight, the baseline-subtracted lightscattering signal can be substituted for the product of weight averagemolecular weight and weight fraction in equation (2) below:

$\begin{matrix}{{\left. {{{\left. {{{\left. a \right)\mspace{14mu} \overset{\_}{Mn}} = \frac{\sum\limits^{i}{Wf}_{i}}{\sum\limits^{i}\left( \frac{{Wf}_{i}}{M_{i}} \right)}}b} \right)\mspace{14mu} \overset{\_}{Mw}} = \frac{\sum\limits^{i}\left( {{Wf}_{i}*M_{i}} \right)}{\sum\limits^{i}{Wf}_{i}}}c} \right)\mspace{14mu} \overset{\_}{Mz}} = \frac{\sum\limits^{i}\left( {{Wf}_{i}*M_{i}^{2}} \right)}{\sum\limits^{i}\left( {{Wf}_{i}*M_{i}} \right)}} & (2)\end{matrix}$

Monomodal distribution was characterized according to the weightfraction of the highest temperature peak in temperature rising elutionfractionation (typically abbreviated as “TREF”) data as described, forexample, in Wild et al., Journal of Polymer Science, Poly. Phys. Ed.,Vol. 20, p. 441 (1982), in U.S. Pat. No. 4,798,081 (Hazlitt et al.), orin U.S. Pat. No. 5,089,321 (Chum et al.), the disclosures of all ofwhich are incorporated herein by reference. In analytical temperaturerising elution fractionation analysis (as described in U.S. Pat. No.4,798,081 and abbreviated herein as “ATREF”), the composition to beanalyzed is dissolved in a suitable hot solvent (for example, 1,2,4trichlorobenzene), and allowed to crystallized in a column containing aninert support (for example, stainless steel shot) by slowly reducing thetemperature. The column was equipped with both an infra-red detector anda differential viscometer (DV) detector. An ATREF-DV chromatogram curvewas then generated by eluting the crystallized polymer sample from thecolumn by slowly increasing the temperature of the eluting solvent(1,2,4 trichlorobenzene). The ATREF-DV method is described in furtherdetail in WO 99/14271, the disclosure of which is incorporated herein byreference.

Long Chain Branching was determined according to the methods known inthe art, such as gel permeation chromatography coupled with low anglelaser light scattering detector (GPC-LALLS) and gel permeationchromatography coupled with a differential viscometer detector (GPC-DV).

Short chain branch distribution breadth (SCBDB) was determined based inthe data obtained via analytical temperature rising elutionfractionation (ATREF) analysis, described hereinbelow in furtherdetails. First, a cumulative distribution of the elution curve wascalculated beginning at 30° C. and continuing to and including 109° C.From the cumulative distribution, temperatures were selected at 5 weightpercent (T₅) and 95 weight percent (T₉₅). These two temperatures werethen used as the bounds for the SCBDB calculation. The SCBDB is thencalculated from the following equation:

${SCBDB} = \sqrt{\frac{\sum\limits_{i}{w_{i}\left( {T_{i} - T_{w}} \right)}^{2}}{\sum\limits_{i}w_{i}}}$

for all T_(i) including and between T₅ and T₉₅. T_(i) is the temperatureat the ith point on the elution curve, w_(i) is the weight fraction ofmaterial from each temperature on the elution curve, and T_(w) is theweight-averaged temperature of the elution curve (Σ(w_(i)T_(i))/Σw_(i))between and including T₅ and T₉₅.

Analytical temperature rising elution fractionation (ATREF) analysis wasconducted according to the method described in U.S. Pat. No. 4,798,081and Wilde, L.; Ryle, T. R.; Knobeloch, D. C.; Peat, I. R.; Determinationof Branching Distributions in Polyethylene and Ethylene Copolymers, J.Polym. Sci., 20, 441-455 (1982), which are incorporated by referenceherein in their entirety. The composition to be analyzed was dissolvedin trichlorobenzene and allowed to crystallize in a column containing aninert support (stainless steel shot) by slowly reducing the temperatureto 20° C. at a cooling rate of 0.1° C./min. The column was equipped withan infrared detector. An ATREF chromatogram curve was then generated byeluting the crystallized polymer sample from the column by slowlyincreasing the temperature of the eluting solvent (trichlorobenzene)from 20 to 120° C. at a rate of 1.5° C./min.

Comonomer content was measured using C₁₃ NMR, as discussed in Randall,Rev. Macromol. Chem. Chys., C29 (2&3), pp. 285-297, and in U.S. Pat. No.5,292,845, the disclosures of which are incorporated herein by referenceto the extent related to such measurement. The samples were prepared byadding approximately 3 g of a 50/50 mixture oftetrachloroethane-d2/orthodichlorobenzene that was 0.025M in chromiumacetylacetonate (relaxation agent) to 0.4 g sample in a 10 mm NMR tube.The samples were dissolved and homogenized by heating the tube and itscontents to 150° C. The data was collected using a JEOL Eclipse 400 MHzNMR spectrometer, corresponding to a 13C resonance frequency of 100.6MHz. Acquisition parameters were selected to ensure quantitative 13Cdata acquisition in the presence of the relaxation agent. The data wasacquired using gated 1H decoupling, 4000 transients per data file, a 4.7sec relaxation delay and 1.3 second acquisition time, a spectral widthof 24,200 Hz and a file size of 64K data points, with the probe headheated to 130° C. The spectra were referenced to the methylene peak at30 ppm. The results were calculated according to ASTM method D5017-91.

Melt temperature and crystallization temperature were measured viaDifferential Scanning calorimetry (DSC). All of the results reportedhere were generated via a TA Instruments Model Q1000 DSC equipped withan RCS (refrigerated cooling system) cooling accessory and an autosampler. A nitrogen purge gas flow of 50 ml/min was used throughout. Thesample was pressed into a thin film using a press at 175° C. and 1500psi (10.3 MPa) maximum pressure for about 15 seconds, then air-cooled toroom temperature at atmospheric pressure. About 3 to 10 mg of materialwas then cut into a 6 mm diameter disk using a paper hole punch, weighedto the nearest 0.001 mg, placed in a light aluminum pan (ca 50 mg) andthen crimped shut. The thermal behavior of the sample was investigatedwith the following temperature profile: The sample was rapidly heated to180° C. and held isothermal for 3 minutes in order to remove anyprevious thermal history. The sample was then cooled to −40° C. at 10°C./min cooling rate and was held at −40° C. for 3 minutes. The samplewas then heated to 150° C. at 10° C./min heating rate. The cooling andsecond heating curves were recorded.

Vinyl unsaturations were measured according to ASTM D-6248-98.

Trans unsaturations were measured according to ASTM D-6248-98.

Methyl groups were determined according to ASTM D-2238-92.

Resin stiffness was characterized by measuring the Flexural Modulus at 5percent strain and Secant Modulii at 1 percent and 2 percent strain, anda test speed of 0.5 inch/min (13 mm/min) according to ASTM D-790-99Method B.

Tensile testing is determined via ASTM D-638 at 2 inches per minutestrain rate.

Tensile impact was determined according to ASTM D-1822-06.

The capillary viscosity measured at 190° C. on a Goettfert Rheograph2003 fitted with a flat entrance (180°) die of length 20 mm and diameterof 1 mm at apparent shear rates ranging from 100 to 6300 s⁻¹.Rabinowitsch correction was applied to account for the shear thinningeffect. The corrected shear rate and shear viscosity were reportedherein.

Handfeel test was conducted according to the following process todetermine the following four attributes on a scale from 0 to 15: (1)Smoothness; (2) Waxy; (3) Stiffness; and (4) Hand Friction.

The following four attributes (1) Smoothness; (2) Waxy; and (3) HandFriction were analyzed using fabric covered napkins. Four napkins werelaid on top of one another and the woven fabric sheet was placed on topof the napkins and taped into place to prevent curling. The napkins wereHoffmaster Linen-Like Dinner napkins, 12″×17″, white. The 4.25″×8.5″area used for the evaluation was not embossed, textured, or quilted.

The attribute Stiffness was analyzed using a single sheet of fabric.

The samples were evaluated by a panel comprising of 20 trainedindividuals. Each of the 20 panelists evaluated (touched) the outside ofthe samples and rated the amount of Smoothness, Waxy, Stiffness, andHand Friction characteristics of each sample on a scale from 0 to 15vis-á-vis a control group, as described herein below. These ratings wereaveraged and reported.

Each attribute was analyzed using an F-statistic in Analysis of Variance(ANOVA) to determine if there were any significant differences among thesamples in the multiple comparisons. The F-ratio in the ANOVA indicatedsamples to be significantly different, so a Fisher's Least SignificantDifference (LSD) was calculated to determine One-at-a-Time multiplecomparisons. The Fisher's LSD test is used for pairwise comparisons whena significant F-value has been obtained.

A human sensory panel of 20 was used to evaluate article attributesbelieved to be associated with the perception of softness. Theattributes are defined as follows. Twenty trained panelists evaluatedthe samples, with a random order of presentation, and random three-digitlabeling for the samples. The samples were evaluated for smoothness,waxy, stiffness, and hand friction. Additional information may be foundin Sensory Evaluation Techniques, 3^(rd) Edition, CRC Press byMeilgaard, Civille, and Carr.

Hand friction is evaluated by moving one's hand across the surface ofthe composite structure. The sample is placed flat on a table,evaluation side up. Using the weight of the hand and forearm, the handis moved horizontally across the surface in all four directions parallelto the edges. Hand friction is measured on a scale from 0 to 15, where 0is the no drag (most slip), and 15 is the most drag (least slip), asshown below.

The samples were compared against the following hand-friction controlgroup.

Rating Scale Value Fabric Type 1.4 Filament nylon 6.6 semidull taffeta3.5 Cotton Egyptian shirting 7.2 Cotton print cloth 10.0 Cotton flannel14.2 Cotton terry cloth

Smoothness evaluated the amount of abrasive particles on the surface.The sample is placed flat, and one's dominant hand is placed on top ofthe sample; using just the weight of the fingers, move the fingersacross the surface of the sample. Smoothness is measured on a scale from0 to 15, were 0 is the most smooth (least rough), and 15 is the leastsmooth (most rough), as shown below.

The samples were compared against the following smoothness controlgroup.

Rating Scale Value Fabric Type 2.1 Bl. mercerized cotton poplin 4.9 Armycarded cotton sateen bleached 9.5 Cotton momie fabric 13.6 #8 Cottonduck greige

Waxy attribute evaluates the amount of waxy feel on the surface and theinterior of the sample. The sample is placed flat, and one's dominanthand is placed on top of the sample; using just the weight of thefingers, move fingers across the surface of the sample. Waxy is alsomeasured on a scale from 0 to 15, where 0 is the most waxy, and 15 isnot waxy, as shown below.

The samples were compared against the following waxy control group.

Rating Scale Value Fabric Type 2.0 Polyethylene (ethylene-octene)(Affinity) non-woven 9.3 Filament nylon 6 tricot-bright 13.0 100%pre-shrunk cotton

Stiffness evaluates the degree to which the sample feels pointed,ridged, or cracked. The sample is placed flat, and one's dominant handis placed on top of the sample; position so the fingers are pointingtoward the top of the sample. The fingers are then closed, gathering thecomposite sample with fingers toward palm. The non-dominant hand is thenused to press the sample into the cupped dominant hand. The dominanthand is then closed slightly and the sample manipulated by rotating thesample in the palm. Stiffness is also measured on a scale from 0 to 15,where 0 is the least stiff (most pliable), and 15 is the stiffest (leastpliable), as shown below.

The samples were compared against the following stiffness control group.

Rating Scale Value Fabric Type 1.3 Polyester/cotton 50/50 single knittubular 4.7 Mercerized cotton print cloth 8.5 Mercerized combed cottonpoplin 14.0 Cotton organdy

The present invention may be embodied in other forms without departingfrom the spirit and the essential attributes thereof, and, accordingly,reference should be made to the appended claims, rather than to theforegoing specification, as indicating the scope of the invention.

1. A polyethylene composition comprising: less than or equal to 100percent by weight of the units derived from ethylene; less than 20percent by weight of units derived from one or more α-olefin comonomers;wherein said polyethylene composition has a density in the range of0.920 to 0.970 g/cm³, a molecular weight distribution (M_(w)/M_(n)) inthe range of 1.70 to 3.5, a melt index (I₂) in the range of 0.2 to 1000g/10 minutes, a molecular weight distribution (M_(z)/M_(w)) in the rangeof less than 2.5, vinyl unsaturation of less than 0.1 vinyls per onethousand carbon atoms present in the backbone of said composition. 2.The polyethylene composition according to claim 1, wherein saidpolyethylene composition has a density in the range of 0.930 to 0.960g/cm³, and a melt index (I₂) in the range of 1 to 50 g/10 minutes. 3.The polyethylene composition according to claim 1, wherein saidpolyethylene composition has a vinyl unsaturation of less than 0.05vinyls per one thousand carbon atoms present in the backbone of thecomposition.
 4. The polyethylene composition according to claim 1,wherein said polyethylene composition has less than 2 peaks on anelution temperature-eluted amount curve determined by continuoustemperature rising elution fraction method at equal or above 30° C.,wherein the purge peak which is below 30° C. is excluded.
 5. Thepolyethylene composition according to claim 1, wherein said polyethylenecomposition comprises less than 15 percent by weight of the unitsderived from one or more α-olefin comonomers.
 6. The polyethylenecomposition according to claim 1, wherein said polyethylene compositionis free of long chain branching.
 7. The polyethylene compositionaccording to claim 1, wherein said polyethylene composition comprisesless than 100 parts by weight of hafnium residues remaining from thehafnium based metallocene catalyst per one million parts of polyethylenecomposition.
 8. A process for producing a polyethylene compositioncomprising the steps of: (co)polymerizing ethylene and optionally one ormore α-olefin comonomers in the presence of a hafnium based metallocenecatalyst via a gas phase (co)polymerization process in a single stagereactor; thereby producing said polyethylene composition having adensity in the range of 0.920 to 0.970 g/cm³, a molecular weightdistribution (M_(w)/M_(n)) in the range of 1.70 to 3.5, a melt index(I₂) in the range of 0.2 to 1000 g/10 minutes, a molecular weightdistribution (M_(z)/M_(w)) in the range of less than 2.5, vinylunsaturation of less than 0.1 vinyls per one thousand carbon atomspresent in the backbone of said composition.
 9. A polyethylenecomposition comprising the (co)polymerization reaction product ofethylene and optionally one or more α-olefin comonomers in the presenceof a hafnium based metallocene catalyst via a gas phase(co)polymerization process in a single stage reactor; wherein saidpolyethylene composition has a density in the range of 0.920 to 0.970g/cm³, a molecular weight distribution (M_(w)/M_(n)) in the range of1.70 to 3.5, a melt index (I₂) in the range of 0.2 to 1000 g/10 minutes,a molecular weight distribution (M_(z)/M_(w)) in the range of less than2.5, vinyl unsaturation of less than 0.06 vinyls per one thousand carbonatoms present in the backbone of said composition.
 10. A fibercomprising: a polyethylene composition comprising: less than or equal to100 percent by weight of the units derived from ethylene; less than 20percent by weight of units derived from one or more α-olefin comonomers;wherein said polyethylene composition has a density in the range of0.920 to 0.970 g/cm³, a molecular weight distribution (M_(w)/M_(n)) inthe range of 1.70 to 3.5, a melt index (I₂) in the range of 0.2 to 1000g/10 minutes, a molecular weight distribution (M_(z)/M_(w)) in the rangeof less than 2.5, vinyl unsaturation of less than 0.1 vinyls per onethousand carbon atoms present in the backbone of said composition. 11.The fiber according to claim 10, wherein said fiber has a denier perfilament in the range of less than 50 g/9000 m.
 12. The fiber accordingto claim 10, wherein said fiber has a tenacity in the range of 0.1 to 5g/denier.
 13. The fiber according to claim 10, wherein said fiber has anelongation measured in percent of less than
 1000. 14. The fiberaccording to claim 10, wherein said fiber has a boiling water shrinkmeasured in percent after being annealed at 120° C. in the range of lessthan
 30. 15. The fiber according to claim 10, wherein said fiber is astaple fiber or a continuous fiber.
 16. A process for making a fibercomprising the steps of: selecting a polyethylene compositioncomprising; less than or equal to 100 percent by weight of the unitsderived from ethylene; less than 20 percent by weight of units derivedfrom one or more α-olefin comonomers; wherein said polyethylenecomposition has a density in the range of 0.920 to 0.970 g/cm³, amolecular weight distribution (M_(w)/M_(n)) in the range of 1.70 to 3.5,a melt index (I₂) in the range of 0.2 to 1000 g/10 minutes, a molecularweight distribution (M_(z)/M_(w)) in the range of less than 2.5, vinylunsaturation of less than 0.06 vinyls per one thousand carbon atomspresent in the backbone of said composition; spinning said polyethylenecomposition into a fiber; thereby forming said fiber.
 17. The processfor making a fiber according to claim 16, wherein said process furthercomprises the step of orienting said fiber.
 18. The process for making afiber according to claim 17, wherein said fiber is oriented via colddrawing.
 19. The process for making a fiber according to claim 17,wherein process further comprises the step of annealing said fiber. 20.The process for making a fiber according to claim 19, wherein saidannealing step is carried out at 100° C. or above.
 21. The process formaking a fiber according to claim 19, wherein said fiber is annealed ata fixed length.
 22. The process for making a fiber according to claims19, wherein said fiber is drawn at least 1.5X, wherein X is the ratio ofthe draw roll speed to the feed roll speed.
 23. A process forfabricating a fabric comprising the steps of: providing a fibercomprising a polyethylene composition comprising; less than or equal to100 percent by weight of the units derived from ethylene; less than 20percent by weight of units derived from one or more α-olefin comonomers;wherein said polyethylene composition has a density in the range of0.920 to 0.970 g/cm³, a molecular weight distribution (M_(w)/M_(n)) inthe range of 1.70 to 3.5, a melt index (I₂) in the range of 0.2 to 1000g/10 minutes, a molecular weight distribution (M_(z)/M_(w)) in the rangeof less than 2.5, vinyl unsaturation of less than 0.1 vinyls per onethousand carbon atoms present in the backbone of said composition;forming said fiber into said fabric via a process selected from thegroup consisting of weaving process, knitting process, melt blownprocess, spunbond process, air laid process, needle punch process,hydroentangling process, electrospinning process, and combinationsthereof.
 24. A fabric comprising: one or more fibers comprising: apolyethylene composition comprising: less than or equal to 100 percentby weight of the units derived from ethylene; less than 20 percent byweight of units derived from one or more α-olefin comonomers; whereinsaid polyethylene composition has a density in the range of 0.920 to0.970 g/cm³, a molecular weight distribution (M_(w)/M_(n)) in the rangeof 1.70 to 3.5, a melt index (I₂) in the range of 0.2 to 1000 g/10minutes, a molecular weight distribution (M_(z)/M_(w)) in the range ofless than 2.5, vinyl unsaturation of less than 0.1 vinyls per onethousand carbon atoms present in the backbone of said composition. 25.The fabric according to claim 24, wherein said fabric is selected fromthe group consisting of woven fabric, non-woven fabric, and combinationsthereof.
 26. The woven fabric according to claim 25, wherein said wovenfabric has an abrasion resistance in the range of less 5 percent byweight of abraded fiber per weight of the fabric prior to abrasiontesting.
 27. The fabric according to claim 24, wherein said fabric is anarticle selected from the group consisting of upholstery, apparel, wallcovering, carpet, diaper topsheet, diaper backsheet, medical fabric,surgical wrap, hospital gown, wipe, textile, and geotextile.
 28. Thefabric according to claim 24, wherein said fabric is a woven fabrichaving an abrasion resistance in the range of less 5 percent by weightof abraded fiber per weight of the fabric prior to abrasion testing. 29.The fabric according to claim 24, wherein said fabric comprises one ormore fibers having a denier per filament in the range of less than 5g/9000 m, e.g. 2 g/9000 m, and the fabric has a smoothness value in therange of less than
 2. 30. The fabric according to claim 24, wherein saidfabric comprises one or more fibers having a denier per filament in therange of less than 5 g/9000 m, e.g. 2 g/9000 m, and the fabric has a waxvalue in the range of greater than
 7. 31. The fabric according to claim24, wherein said fabric comprises one or more fibers having a denier perfilament in the range of less than 5 g/9000 m, e.g. 2 g/9000 m, and thefabric has a hand friction value in the range of less than 3.5.
 32. Thefabric according to claim 24, wherein said fabric comprises one or morefibers having a denier per filament in the range of less than 5 g/9000m, e.g. 2 g/9000 m, and the fabric has a stiffness value in the range ofless than 1.1.